US 2022/0144706 A1 · HIGH STRENGTH, TOUGH, COAL AND COAL BY-PRODUCT BASED COMPOSITE CERAMICS

Abstract

A composite material, compositions, processes and methods of using coal and coal by-products composite ceramics is provided for use as a safe, non-toxic material for construction, building and architecture components. The composite material disclosed herein is formed from resin/coal aggregates that contain and prevent the release of harmful impurities that naturally occur in both coal and coal by-products while the advantages of coal-based composites are made available to the building industry. The strength, density and porosity of the composites can be tailored within a wide range to fit the final application by controlling the materials, form factor and processing parameters during fabrication.

Claims20

Dependent claims

A coal-based ceramic composite aggregate having one resin coating that prevents the release or leaching out of harmful impurities from coal or coal by-products, comprising:

a plurality of powdered coal particles and a plurality of powdered coal by-product particles each having a particle size effective diameter ranging from approximately 0.01 micron up to approximately 100 microns;
a pre-ceramic polymer resin selected from an inorganic polymer resin mixed with the plurality of powdered coal particles and the plurality of powdered coal by-product particles to form a plurality of resin-coated coal particles, wherein the plurality of resin-coated coal particles bond together during mixing to produce a coal-based composite aggregate with multimodal particle size distribution in an effective diameter range between approximately 5 microns up to approximately 5 millimeters and the coal-based composite aggregate is molded or extruded or subsequently pressure-formed before curing to form a green body composite aggregate that is subsequently pyrolyzed to produce a coal-based ceramic composite aggregate.

A coal-based ceramic composite having a dual coating of resin for production of durable, building construction material, comprising:

a plurality of powdered coal particles and a plurality of powdered coal by-product particles each having a particle size effective diameter ranging from approximately 0.01 micron up to approximately 100 microns;
a first pre-ceramic polymer resin selected from an inorganic polymer resin, wherein the powdered coal and powdered coal by-product is mixed with the inorganic polymer resin to form a plurality of resin-coated powdered coal particles and powdered coal by-product particles to produce afirst coal-based composite aggregate that is processed to produce a first coal-based ceramic composite;
the first coal-based ceramic composite is crushed, ground, and milled to make a plurality of aggregate particles wherein a multimodal particle size distribution is in a range from approximately 5 microns to approximately 5 millimeters in effective diameter;
the plurality of aggregate particles having multimodal particle size distribution is mixed with a second pre-ceramic polymer resin to form a dual resin-coated coal-based composite that is molded or extruded or pressure-formed before curing to form a green body building or construction part that is pyrolyzed to produce a dual resin-coated, coal-based ceramic composite.

1 more element

Dependencies are inferred from the claim text.

High strength, tough, coal and coal by-product based composite ceramics

Life of this patent

High strength, tough, coal and coal by-product based composite ceramics

Life of this patent

Abstract

Claims20