# US 2014/0194328 A1 · Thermoset ceramic compositions and a method of preparation therefor

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- Number: US 2014/0194328 A1
- Document ID: US20140194328A1
- Status: Published application
- Kind: A1
- Application number: 13/832,328
- Filed: 2013-03-15
- Published: 2014-07-10
- Earliest claimed: 2013-01-07
- Inventors: Vince Alessi
- Web page: https://patentgrep.com/patent/US20140194328A1

## CPC

- C09K 8/80: Compositions for reinforcing fractures, e.g. compositions of proppants used to keep the fractures open
- C04B 38/009: {Porous or hollow ceramic granular materials, e.g. microballoons (C04B18/027, C04B20/002 take precedence)}
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE

## Abstract

Thermoset ceramic compositions and a method of preparation of such compositions. The compositions are advanced organic/inorganic hybrid composite polymer ceramic alloys. The material combine strength, hardness and high temperature performance of technical ceramics with the strength, ductility, thermal shock resistance, density, and easy processing of the polymer. Consisting of a branched backbone of silicon, alumina, and carbon, the material undergoes sintering at 7 to 300 centigrade for 2 to 94 hours from water at a pH between 0 to 14, humidity of 0 to 100%, with or without vaporous solvents.

## Claims

### Claim 1

A composition of matter comprising:
a polymer of aluminum, silicon, carbon, and oxygen.

### Claim 2

A composition of matter provided by the incipient materials:
a. aluminum oxide,
b. silicon oxide,
c. carbon, and, a source of
d. divalent cations.

### Claim 3 (depends on 2)

A composition of matter as claimed in claim 2 wherein the composition of matter is a gel.

### Claim 4 (depends on 2)

The composition as claimed in claim 2 wherein the divalent cations are selected from the group consisting of calcium, and magnesium.

### Claim 5 (depends on 2)

A composition of matter as claimed in claim 2 wherein, in addition, metal is added.

### Claim 6 (depends on 2)

A composition of matter as claimed in claim 2 wherein, in addition, fibers are added.

### Claim 7 (depends on 2)

A composition of matter as claimed in claim 2 wherein, in addition, other metallic oxides are added.

### Claim 8 (depends on 1)

A method of preparation of a composition of claim 1, said method comprising:
a. providing a mixture of aluminum oxide and silicon oxide;
b. providing a mixture, having a basic pH, in a slurry form, of
i. water,
ii. a source of OH−,
iii. carbon, and,
iv. a source of divalent cations;
c. mixing A. and B. together using shear force to form a stiff gel;
d. exposing the product of C. to a temperature in the range of 160° F. to 250° F. for a period of time to provide a thermoset ceramic.

### Claim 9 (depends on 8)

The method as claimed in claim 8 wherein the temperature range is from 175° F. to 225° F.

### Claim 10 (depends on 8)

The method as claimed in claim 8 wherein the time period for heating is 2 to 6 hours.

### Claim 11 (depends on 8)

The method as claimed in claim 8 wherein the time period of heating is in excess of 6 hours.

### Claim 12 (depends on 8)

A product when prepared by the method as claimed in claim 8.

### Claim 13 (depends on 2)

A method of hydraulically fracturing oil and gas wells, said method comprising using the composition as claimed in claim 2 as the proppant.

### Claim 14 (depends on 2)

A solid substrate when coated with a composition as claimed in claim 2.

### Claim 15

A composition of matter consisting of amorphous polymer comprising metal carbon bonds and metal oxide bonds.

### Claim 16 (depends on 15)

A composition as claimed in claim 15 wherein the ratio of metal carbon bonds to metal oxygen bonds is 0.1-1:1.

### Claim 17 (depends on 15)

A composition as claimed in claim 15 wherein the metals consist of silicon and aluminum.

### Claim 18 (depends on 15)

A composition as claimed in claim 15 wherein the amorphous nature is exhibited by a Raman metal oxide peak between 1300 and 1400 wavenumbers half height full width ratio of greater than 0.1.

### Claim 19 (depends on 18)

A composition as claimed in claim 18 wherein the half height full width ratio is greater than 0.12.