US-12617712-B2 - Fused layer and core

Abstract

A robust coated core comprising a composite with a fused or sintered coating.

Inventors

• Adam Bartel
• Scott Bohnen
• Kurt Heikkila

Assignees

• Tundra Composites, LLC

Dates

Publication Date

20260505

Application Date

20220712

Claims (11)

1. 1 . A composite structure comprising: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and (ii) at least one continuous fused interphase layer covering the outer surface of the core bead, wherein the at least one continuous fused interphase layer consists essentially of fused soda lime glass particulates and an inorganic central atom derived from an interfacial modifier and wherein the core bead does not melt.
2. 2 . A composite structure comprising: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and (ii) at least one continuous fused interphase layer covering the outer surface of the core bead, wherein the at least one fused interphase layer consisting essentially of a plurality of soda lime glass particulates, each particulate having a longest dimension of 10 micrometers or less, and an interfacial modifier having a central atom and two or more organic substituents; and heating the resulting coated bead to melt the soda lime glass particulates, followed by cooling to form the at least one fused layer and wherein the core bead does not melt.
3. 3 . The composite structure according to claim 2 , wherein the central atom of the interfacial modifier is selected from the group consisting of titanium, zirconium, hafnium, samarium, strontium, neodymium, yttrium, boron, cobalt, phosphorous, aluminum and zinc.
4. 4 . The composite structure according to claim 2 , wherein interfacial modifier has the following structure: M(R1) n (R2) m wherein M is a central atom selected from such inorganic central atoms; R1 is a group consisting 5 of a hydrolysable organic group; R2 is a group consisting of an organic moiety, and m and n are integers of 1 to 4 depending on valence and m+n=2-4.
5. 5 . The composite structure according to claim 2 , wherein the core bead is spherical.
6. 6 . The composite structure according to claim 2 , wherein the diameter of the core bead is from about 1000 to about 1500 micrometers.
7. 7 . The composite structure according to claim 2 , comprising one or more additional continuous fused interphase layers consisting of fused soda lime glass particulates and central atoms from an interfacial modifier having a central atom and two or more organic substituents, wherein the one or more additional continuous fused interphase layers are disposed on the at least one fused interphase layer.
8. 8 . The composite structure according to claim 2 , wherein the at least one fused interphase layer and any additional continuous fused interphase layers each has a thickness of from about 10 to about 50 micrometers.
9. 9 . The composite structure according to claim 2 , wherein the at least one fused interphase layer and any additional continuous fused interphase layers each has a thickness of from about 20 to about 30 micrometers.
10. 10 . A composite structure comprising: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and (ii) at least one continuous fused interphase layer covering the outer surface of the core bead, wherein the at least one continuous fused interphase layer consists of fused soda lime glass particulates and an inorganic central atom derived from an interfacial modifier and wherein the core bead does not melt.
11. 11 . A composite structure comprising: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and (ii) at least one continuous fused interphase layer covering the outer surface of the core bead, wherein the at least one fused interphase layer is formed by: coating the outer surface of the core bead with a mixture consisting of a plurality of soda lime glass particulates, each particulate having a longest dimension of 10 micrometers or 20 less, and an interfacial modifier having a central atom and two or more organic substituents; and heating the resulting coated bead to melt the soda lime glass particulates, followed by cooling to form the at least one fused layer and wherein the core bead does not melt.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63/254,416, filed Oct. 11, 2021. This application is hereby incorporated by reference in its entirety. FIELD The embodiments of this application relate generally to composites that have a fused interphase layer on a core bead. The claims relate to an interphase layer that is useful in forming a functional composite. The composite comprises a core bead with an interphase coating that can act to bond a functional material to the core bead. The functional material can provide a catalytic, chemical, or physical property or mode of action not obtained by the core bead or the interphase coating. BACKGROUND Conventional functional particles have a known useful lifetime. The functional lifetime is limited by contamination of the functional particle from the use environment. Further, the lifetime is limited by the loss of functional material from the surface of the article during use. Lastly, the functional lifetime is limited by the decomposition or poisoning of the functional particulates. There is a substantial need to develop an easily manufactured composite comprising functional particulate. A need is seen to reduce a manufacturing cost and improve manufacturing methods of the functional particle carried on a substrate. A substantial need exists for a functional particle article or element using the functional particle substrate. To remedy the problems arising from the use of conventional material/particle coatings an improved functional composite has been developed. BRIEF DESCRIPTION Briefly as disclosed herein, we have found a core with a fused layer bonded to the core. We have found that use of a coating composition comprising a blend of an interfacial modifier (IM), and a glass particulate provides a robust layer for later uses. Sintering a finely divided glass particulate and the interfacial modifier results in the rapid and uniform formation of one or more layers of a fused material surrounding the core bead. The fused nature of the composite provides a durable robust composite that can survive a harsh use environment. We have seen that the entire outer surface of the core bead, or virtually the entire surface of the core bead, can be covered with the interphase layer. Disclosed herein is a composite structure comprising, consisting essentially of or consisting of: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and(ii) at least one continuous fused interphase layer covering the outer surface of the core bead,wherein the at least one continuous fused interphase layer consists of fused soda lime glass particulates and an inorganic metal or metalloid central atom derived from an interfacial modifier. The inorganic atom chosen from any metal or metalloid of groups 3 to 13 of the Periodic Table. Also disclosed is composite structure comprising, consisting essentially of or consisting of: (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of from about 500 to about 2000 micrometers; and(ii) at least one continuous fused interphase layer covering the outer surface of the core bead,wherein the at least one fused interphase layer is formed by:(a) coating the outer surface of the core bead with a combination consisting of a plurality of soda lime glass particulates, each particulate having a longest dimension of 10 micrometers or less, and an interfacial modifier having a central atom and two or more organic substituents; and(b) heating the resulting coated bead to melt the soda lime glass particulates, followed by cooling to form the at least one fused layer. Also disclosed is a method of forming a composite structure comprising, consisting essentially of or consisting of (i) a substantially spherical soda lime glass core bead with an outer surface and a diameter of 500 to 2000 micrometers; and (ii) at least one continuous fused interphase layer on the outer surface of the core bead, the method comprising:(a) coating the outer surface of the core bead with a combination consisting of a plurality of soda lime glass particulates, each particulate having a longest dimension of 10 micrometers or less, and an interfacial modifier having a central atom and two or more organic substituents; and(c) heating the resulting coated bead to melt the soda lime glass particulates, followed by cooling to form the at least one fused layer. In this context the composite must be free of any polymer and organic component. The composite must be free of any component that interferes with forming a continuous layer of glass particulate and interfacial modifier (IM) or prevents fusion. The term “composite” refers to a combination of core bead, a finely divided glass particulate and a central atom derived from an interfacial modifier in a fused layer surrounding each core. The term “coating