Microstructured high-temperature hybrid material, its composite material and method of making

A composite material that exhibits strength, stiffness and ability to withstand high temperatures,

• said composite material comprising a hybrid material and an additional solid ingredient,
• said hybrid material essentially consisting of component A and component B,
• said component A being selected from the group consisting of inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof, said component B being selected from the group consisting of elemental carbon, inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof,
• said component B comprising a plurality of units,
• each of said units substantially exhibiting a shape,
• said shape substantially exhibiting a long dimension and a short dimension,
• said short dimension being in a direction that is essentially perpendicular to the direction of said long dimension,
• said short dimension being in the range from 0.1 nm to 0.5 μm,
• said component A comprising a plurality of units,
• each of said units substantially exhibiting a shape,
• said shape substantially exhibiting a long dimension and a short dimension,
• the direction of said short dimension being essentially perpendicular to the direction of said long dimension,
• said short dimension being in the range from 0.1 nm to 50 μm,
• each of the units of component B being substantially in contact with and substantially bonded to at least one of the units of component A,
• the direction of the short dimension of each of the units of component B being essentially parallel to the direction of the short dimension of an adjoining unit of component A.

A method of making a composite material that exhibits strength, stiffness and ability to resist high temperatures,

• said composite material comprising a hybrid material and an additional solid ingredient,
• said hybrid material functioning as a filler and a binder in said composite material,
• said hybrid material essentially consisting of component A and component B,
• said component A being selected from the group consisting of inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof,
• said component B being selected from the group consisting of elemental carbon, inorganic compounds, oxides, carbides, nitrides, borides, and combinations thereof,
• said component B comprising a plurality of units,
• each of said units substantially exhibiting a shape,
• said shape substantially exhibiting a long dimension and a short dimension,
• said short dimension being in a direction that is essentially perpendicular to the direction of said long dimension,
• said short dimension being in the range from 0.1 nm to 0.5 μm,
• said component A comprising a plurality of units,
• each of said units substantially exhibiting a shape,
• said shape substantially exhibiting a long dimension and a short dimension,
• said short dimension being in a direction that is essentially perpendicular to the direction of said long dimension,
• said short dimension being in the range from 0.1 nm to 50 μm,
• each of the units of component B being substantially in contact with and substantially bonded to at least one of the units of component A,
• the direction of the short dimension of each of the units of component B being essentially parallel to the direction of the short dimension of an adjoining unit of component A,
• said method comprising heating a composition comprising an organo-modified mineral and said additional solid ingredient,
• said heating being conducted under pressure in the essential absence of oxygen,
• the temperature of said heating being in the range from 400° C. to 3000° C. and preferably in the range from 800° C. to 1500° C., and
• said pressure being in the range from 1 MPa to 100 MPa and preferably in the range from 10 MPa to 30 MPa,
• said organo-modified mineral essentially consisting of component I and component II,
• said component I being selected from the group consisting of minerals, silicate minerals, and combinations thereof, such that component A is formed from component I during said heating,
• said component II being selected from the group consisting of organic compounds, organometallic compounds, organophosphorus compounds, organosilicon compounds, organoboron compounds, organobismuth compounds, metallocenes, and combinations thereof, such that component B is formed from component II during said heating.