Shaped article and composite material and method for producing same

A composite material for producing a shaped article, comprising

• (A) inorganic particles of a size of from about 50 .ANG. to about 0.5.mu.,
• (B) solid particles having a size of the order of 0.5-100.mu., and being at least one order of magnitude larger than the respective particles stated under (A), and
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of about 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800, said particles having a size of 100.mu.-0.1 m, a liquid, and a surface-active dispersing agent,
• the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, the amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm.sup.2,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles (A),
• with the proviso that when additional bodies D are not present or are present and consist of sand and/or stone, at least 20% by weight of the particles B are Portland cement particles.

A composite material for producing a shaped article, comprising

• (A) inorganic particles of a size of from about 50 .ANG. to about 0.5.mu.,
• (B) solid particles having a size of the order of 0.5-100.mu., and being at least one order of magnitude larger than the respective particles stated under (A),
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of about 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800, said particles having a size of 100.mu.-0.1 m, and a surface-active dispersing agent,
• the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm.sup.2, when an amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B has been added,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles (A),
• with the proviso that when additional bodies D are not present or are present and consist of sand and/or stone, at least 20% by weight of the particles B are Portland cement particles.

A process for preparing a shaped article selected from the group consisting of in situ cast oil well walls;

• duct fillings;
• fissure fillings;
• sheets;
• panels and tiles of thin-walled plane or corrugated shape;
• corrosion protecting covers applied on steel and concrete members;
• pipes;
• tubes;
• electrically insulating members;
• nuclear shieldings;
• seafloor structures for deep water application;
• brake linings;
• abrasion aggregates;
• containers;
• machine parts;
• and sculptures;
• comprising combining
• (A) inorganic solids particles of a size of from about 50 .ANG. to about 0.5.mu., and
• (B) solid particles having a size of the order of 0.5-100.mu. and being at least one order of magnitude larger than the respective particles stated under (A),
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of about 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800, said particles having a size of 100 .mu.-0.1 m, a liquid, and a surface-active dispersing agent,
• the amount of particles B substantially corresponding to dense packing thereof in the composite material with homogeneously packed particles A in the voids between particles B, the amount of liquid substantially corresponding to the amount necessary to fill out the voids between particles A and B, and the amount of dispersing agent being sufficient to impart to the composite material a fluid to plastic consistency in a low stress field of less than 5 kg/cm.sup.2,
• and optionally
• (D) additional bodies which have at least one dimension which is one order of magnitude larger than the particles A,
• by mechanically mixing the particles A, the liquid, and the surface active dispersing agent, optionally together with particles B, particles C and/or additional bodies D until a viscous to plastic mass has been obtained,
• and therefter, if necessary or if desired, respectively, combining the resulting mass with particles and/or bodies of the type mentioned above (B, C, D) by mechanical means to obtain the desired distribution of the components and finally casting the resulting mass in the desired shape in a stress field optionally with incorporation of particles C and/or additional bodies D during the casting.

A shaped article comprising a coherent matrix,

• the matrix comprising
• (A) homogeneously arranged inorganic solid particles of a size of from about 50 .ANG. to about 0.5.mu., or a coherent structure formed from such homogeneously arranged particles, and
• (B) densely packed solid particles having a size of the order of 0.5-100.mu. and being at least one order of magnitude larger than the respective particles stated under (A), or a coherent structure formed from such densely packed particles,
• the particles A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the particles B,
• the dense packing being substantially a packing corresponding to the one obtainable by gentle mechanical influence on a system of geometrically equally shaped large particles in which locking surface forces do not have any significant effect,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A,
• the article additionally comprising a surface layer or surface layers which has (have) a substantially uniform thickness and a structure which is different from the above-defined structure adjacent to the surface layer or layers.

A shaped article comprising a coherent matrix,

• the matrix comprising
• (A) homogeneously arranged bodies of a size of from about 50 .ANG. to about 0.5.mu., or a coherent structure formed from such homogeneously arranged particles, and
• (B) densely packed bodies having a size of the order of 0.5-100.mu. and being at least one order of magnitude larger than the respective particles stated under (A), or a coherent structure formed from such densely packed particles,
• the bodies A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the bodies B,
• the dense packing being substantially a packing corresponding to the one obtainable by gentle mechanical influence on a system of geometrically equally shaped large particles in which locking surface forces do not have any significant effect,
• the shaped article optionally additionally comprising, embedded in the matrix,
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of above 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800,
• said particles having a size of 100.mu.-0.1 m,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A,
• the bodies A and B being bodies of a gas, a liquid, or a solid.

A cast which consists of a material comprising

• (A) homogeneously arranged inorganic solid particles of a size of from about 50 .ANG. to about 0.5.mu., or a coherent structure formed from such homogeneously arranged particles, and
• (B) densely packed solid particles having a size of the order of 0.5-100.mu. and being at least one order of magnitude lrger than the respective particles stated under (A), or a coherent structure formed from such densely packed particles,
• the particles A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the particles B,
• the dense packing being substantially a packing corresponding to the one obtainable by gentle mechanical influence on a system of geometrically equally shaped large particles in which locking surface forces do not have any significant effect,
• and optionally additionally comprising, embedded in the matrix,
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of above 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800,
• said particles having a size of 100.mu.-0.1 m,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A.

A coating composition comprising a material comprising

• (A) homogeneously arranged inorganic solid particles of a size of from about 50 .ANG. to about 0.5.mu., or a coherent structure formed from such homogeneously arranged particles, and
• (B) densely packed solid particles having a size of the order of 0.5-100.mu. and being at least one order of magnitude larger than the respective particles stated under (A), or a coherent structure formed from such densely packed particles,
• the particles A or the coherent structure formed therefrom being homogeneously distributed in the void volume between the particles B,
• the dense packing being substantially a packing corresponding to the one obtainable by gentle mechanical influence on a system of geometrically equally shaped large particles in which locking surface forces do not have any significant effect,
• and additionally comprising, embedded in the matrix,
• (C) compact-shaped solid particles of a material having a strength exceeding that of ordinary sand and stone used for ordinary concrete, typically a strength corresponding to at least one of the following criteria:
• (1) a die pressure of above 30 MPa at a degree of packing of 0.70, above 50 MPa at a degree of packing of 0.75, and above 90 MPa at a degree of packing of 0.80, (on particles of the material having a size ratio between the largest and smallest particle substantially not exceeding 4 mm),
• (2) a compressive strength of a composite material with the particles embedded in a specified matrix exceeding 170 MPa (in case of a substantial amount of the particles being larger than 4 mm) and 200 MPa (in case of substantially all particles being smaller than 4 mm),
• (3) a Moh's hardness (referring to the mineral constituting the particles) exceeding 7 and
• (4) a Knoop indentor hardness (referring to the mineral constituting the particles) exceeding 800,
• said particles having a size of 100.mu.-0.1 m,
• and optionally
• (D) additional bodies which have at least one dimension which is at least one order of magnitude larger than the particles A.