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US 2021/0002178 A1Published application
Composite tile and method of manufacture
AssigneeDynamic Material Systems, LLC
InventorsWalter Sherwood, Arnold Hill, Gordon Nameni, William Easter
Life of this patent
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Abstract
A composite tile is comprised of coal dust and a pre-ceramic polymer that are mixed together and pyrolyzed to form a ceramic composite. For example, a chemical reaction during pyrolysis chemically converts at least a portion of the coal dust and pre-ceramic polymer to a fire proof ceramic composite suitable for use as a roofing tile either as pyrolyzed or as post-treated to seal cracks and pores formed during pyrolysis.
Claims21
A method of making a coal core composite roofing material comprises:
- mixing polymer, the polymer being selected as a polymer derived ceramic, and coal dust, wherein the coal dust is not a synthetic graphite or carbon dust, to form a mixture;
- forming the mixture into a shape of a roofing tile capable of being installed as any other roofing tile or slate tile;
- and
- pyrolyzing the mixture in an inert atmosphere, wherein the coal dust is not heated above 400 degrees C., prior to step of pyrolyzing, wherein a substantial portion of the coal dust chemically reacts with the polymer derived ceramic and other compounds in the coal dust during the step of pyrolyzing, whereby the coal core composite roofing material has surprisingly improved mechanical properties and fire retardance.
1 more element
Dependencies are inferred from the claim text.