# US 2013/0280528 A1 · Workflow for novel composite materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0280528 A1 - Document ID: US20130280528A1 - Status: Published application - Kind: A1 - Application number: 13/916,521 - Filed: 2013-06-12 - Published: 2013-10-24 - Earliest claimed: 2009-12-15 - Assignees: SDCmaterials, Inc. - Applicants: SDCmaterials, Inc. - Inventors: Maximilian A. BIBERGER - Web page: https://patentgrep.com/patent/US20130280528A1 ## CPC - B01J 23/8926: {Copper and noble metals} - B01J 23/42: Platinum - B01J 37/00: Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts - B28B 23/0087: {Lightweight aggregates for making lightweight articles} - B32B 7/12: using interposed adhesives or interposed materials with bonding properties - B32B 37/12: characterised by using adhesives - B32B 37/14: characterised by the properties of the layers - B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites - B82Y 40/00: Manufacture or treatment of nanostructures - C23C 4/134: Plasma spraying - B28B 11/243: {Setting, e.g. drying, dehydrating or firing ceramic articles (B28B11/242 takes precedence)} - B32B 2037/1253: {curable adhesive} - B32B 2571/02: defensive, e.g. armour plates or anti-ballistic clothing - Y10T 428/2848: Three or more layers - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of making a composite material, the method comprising: providing a tile, wherein the tile comprises an inorganic material; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material. In some embodiments, the exotherm from the foaming of the foamable exothermic material cures the heat-curable adhering material for a time sufficient to unite a solid foam body to the heat-curable adhering material of the tile and the ductile backing material. The method is particularly advantageous in bonding a tile composed of nano-particles to a ductile backing material, as it helps retain the nanoscale properties of the nano-particles in the tile. ## Claims ### Claim 1 A method of making a composite material, the method comprising: providing a tile, wherein the tile comprises an inorganic material; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material. ### Claim 2 (depends on 1) The method of claim 1, wherein the step of bonding comprises: wetting an interior surface of the tile with the heat-curable adhering material; wetting an interior surface of the ductile backing material with the heat-curable adhering material; forming an interior volume between the tile and the ductile backing material, wherein the interior surface of the tile and the interior surface of the ductile backing material are facing one another, and wherein the interior surface of the tile and the interior surface of the ductile backing material each form a boundary of the interior volume; inserting the catalyzed foamable exothermic material into the interior volume after wetting the interior surfaces of the tile and the ductile backing material with the heat-curable adhering material, wherein an amount of catalyzed foamable exothermic material is used that is sufficient to fill the entire interior volume when foamed and form a solid foam body between the tile and the ductile backing material; and allowing the exotherm from the foaming to activate and cure the heat-curable adhering material for a time sufficient to unite the solid foam body to the heat-curable adhering material of the tile and the ductile backing material. ### Claim 3 (depends on 2) The method of claim 2, wherein the step of forming the interior volume comprises sealing the interior volume to a degree sufficient to allow the catalyzed foamable exothermic material to expand and build up interior pressure within the interior volume, thereby creating physical pressurized contact between the catalyzed foamable exothermic material and the heat-curable adhering material of each of the tile and the ductile backing material. ### Claim 4 (depends on 1) The method of claim 1, wherein the adhering material is resin. ### Claim 5 (depends on 1) The method of claim 1, wherein the heat generated during the bonding step does not exceed ¼ of the melting point temperature of the tile. ### Claim 6 (depends on 1) The method of claim 1, wherein the tile comprises sintered nano-powder. ### Claim 7 (depends on 6) The method of claim 6, wherein the tile comprises spark plasma sintered nano-powder. ### Claim 8 (depends on 6) The method of claim 6, wherein the sintered nano-powder comprises ceramic nanopowder. ### Claim 9 (depends on 8) The method of claim 8, wherein the ceramic nano-powder comprises boron carbide. ### Claim 10 (depends on 6) The method of claim 6, wherein the sintered nano-powder comprises ceramic nanopowder and metallic nano-powder. ### Claim 11 (depends on 1) The method of claim 1, wherein the tile comprises sintered powder, the powder comprising particles having a ceramic core with a metallic outer layer. ### Claim 12 (depends on 11) The method of claim 11, wherein the metallic outer layer comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. ### Claim 13 (depends on 1) The method of claim 1, wherein the ductile backing material comprises a plurality of fibers. ### Claim 14 (depends on 1) The method of claim 1, wherein the ductile backing material comprises a plurality of polyethylene fibers. ### Claim 15 A method of making a composite material, the method comprising: providing a plurality of nano-particles; forming a tile from the plurality of nano-particles by performing a spark plasma sintering process on the plurality of nano-particles; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material. ### Claim 16 (depends on 15) The method of claim 15, wherein the step of providing the plurality of nano-particles comprises: applying a plasma stream to a precursor powder, thereby vaporizing the precursor powder; and condensing the vaporized powder, thereby forming the plurality of nano-particles. ### Claim 17 (depends on 15) The method of claim 15, wherein the plurality of nano-particles comprises ceramic material. ### Claim 18 (depends on 17) The method of claim 17, wherein the ceramic material is boron carbide. ### Claim 19 (depends on 15) The method of claim 15, wherein the plurality of nano-particles comprises ceramic material and metallic material. ### Claim 20 (depends on 19) The method of claim 19, wherein the metallic material comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. ### Claim 21 (depends on 15) The method of claim 15, wherein the step of bonding comprises: wetting an interior surface of the tile with the heat-curable adhering material; wetting an interior surface of the ductile backing material with the heat-curable adhering material; forming an interior volume between the tile and the ductile backing material, wherein the interior surface of the tile and the interior surface of the ductile backing material are facing one another, and wherein the interior surface of the tile and the interior surface of the ductile backing material each form a boundary of the interior volume; inserting the catalyzed foamable exothermic material into the interior volume after wetting the interior surfaces of the tile and the ductile backing material with the heat-curable adhering material, wherein an amount of catalyzed foamable exothermic material is used that is sufficient to fill the entire interior volume when foamed and form a solid foam body between the tile and the ductile backing material; and allowing the exotherm from the foaming to activate and cure the heat-curable adhering material for a time sufficient to unite the solid foam body to the heat-curable adhering material of the tile and the ductile backing material. ### Claim 22 (depends on 21) The method of claim 21, wherein the step of forming the interior volume comprises sealing the interior volume to a degree sufficient to allow the catalyzed foamable exothermic material to expand and build up interior pressure within the interior volume, thereby creating physical pressurized contact between the catalyzed foamable exothermic material and the heat-curable adhering material of each of the tile and the ductile backing material. ### Claim 23 (depends on 15) The method of claim 15, wherein the adhering material is resin. ### Claim 24 (depends on 15) The method of claim 15, wherein the heat generated during the bonding step does not exceed ¼ of the melting point temperature of the nano-particles that form the tile. ### Claim 25 (depends on 15) The method of claim 15, wherein the ductile backing material comprises a plurality of fibers. ### Claim 26 (depends on 15) The method of claim 15, wherein the ductile backing material comprises a plurality of polyethylene fibers. ### Claim 27 A composite material comprising: a tile comprising inorganic material; and a ductile backing material, wherein the tile and the ductile backing material are bonded together via foam material and cured adhering material. ### Claim 28 (depends on 27) The composite material of claim 27, wherein: the tile has an interior surface with cured adhering material disposed thereon; the ductile backing material has an interior surface with cured adhering material disposed thereon; and the foam material is disposed in between and in contact with the cured adhering material on the interior surface of the tile and the cured adhering material on the interior surface of the ductile backing material. ### Claim 29 (depends on 27) The composite material of claim 27, wherein the tile comprises sintered nano-particles that have retained their nanoscale properties. ### Claim 30 (depends on 29) The composite material of claim 29, wherein the plurality of nano-particles comprises ceramic material. ### Claim 31 (depends on 30) The composite material of claim 30, wherein the ceramic material is boron carbide. ### Claim 32 (depends on 29) The composite material of claim 29, wherein the plurality of nano-particles comprises ceramic material and metallic material. ### Claim 33 (depends on 32) The composite material of claim 32, wherein the metallic material comprises at least one of copper, tantalum, titanium, molybdenum, and aluminum. ### Claim 34 (depends on 27) The composite material of claim 27, wherein the adhering material is resin. ### Claim 35 (depends on 27) The composite material of claim 27, wherein the ductile backing material comprises a plurality of fibers. ### Claim 36 (depends on 27) The composite material of claim 27, wherein the ductile backing material comprises a plurality of polyethylene fibers.