Dynamic Material Systems LLC

Other

University of Central Florida Research Foundation Inc

Arnold Hill

William Easter

Walter Sherwood

Weifeng Fei

Gordon Nameni

Mark Edward Tellam

Linan An

Kyle Marcus

Matthew Stephens

A complex composite particle is made of a coal dust and binder composite that is pyrolyzed. Constituent portions of the composite react together causing the particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for use as a proppant or in a composite structure.

Complex composite particles and methods

A complex ceramic particle and ceramic composite material may be made of a pretreated coal dust and a polymer derived ceramic that is mixed together and pyrolyzed in a nonoxidizing atmosphere. Constituent portions of the particle mixture chemically react causing particles to increase in density and reduce in size during pyrolyzation, yielding a particle suitable for a plurality of uses including composite articles and proppants.

Functional composite particles

A polymer derived ceramic precursor is selected and mixed with a contaminated recycled electrode material or materials. The mixture is pyrolyzed to form a ceramic or ceramic-carbon composite, reduced to a powder and formed into an electrode of a battery, such as a lithium ion battery.

Electrodes and process for reconditioning contaminated electrode materials for use in batteries

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of ceramic materials and components with a thickness greater than three millimeters (3 mm). A sulfur-free 3D printable formulation comprises a liquid inorganic polymer resin using Stereolithograpy (SLA) printers and Digital Light Processing (DLP) curing of the polymer resin via the chemical bonding of the materials rather than sintering. Thus, the process has shorter manufacturing intervals, significantly lower energy use and produces larger scale ceramic components having less linear shrinkage, less mass loss and high ceramic yield with no corrosive sulfur compounds present in the ceramic component.

Inorganic polymers and compositions for improved 3D printing of larger scale ceramic materials and components

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.

Composite tile and method of manufacture

A material useful as a proppant comprises a core chemically reacted in situ from coal dust and a polymer derived ceramic material, such that at least a portion of the coal dust is chemically converted to a ceramic, nanoparticles, graphene, nanofibers or combinations of any of these.

Fracking proppant and method of manufacture

A composite article is comprised of coal dust, as defined herein, and a polymer derived ceramic material that is pyrolyzed in a substantially non-oxidizing atmosphere. For example, the composite article may be made of a mixture of the coal dust and polymer derived ceramic, from particles formed of a mixture of coal dust and polymer derived ceramic or from complex particle composites comprising a plurality of particles formed of a mixture of coal dust and polymer derived ceramic.

Carbon ceramic composites and methods

Methods, systems, and processes are used to prepare novel ceramic composite structures that are strong, durable, light-weight, high performance and suitable for a myriad of industrial applications, including, but not limited to, ceramic plates of material suitable for use as ballistic armor. The low manufacturing costs of the processes disclosed provide cheaper, faster ways of producing ceramic matrix composites at lower temperatures and allow for the existence of composite materials and structures which currently are not available.

Ceramic composite structures and processing technologies

Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 &#x3bc;m to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. Nano-sized ceramic particles are formed from the green body produced by methods for making bulk, dense composite ceramics. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

Composite ceramics and ceramic particles and method for producing ceramic particles and bulk ceramic particles

Methods, processes, systems, devices and apparatus are provided for additive manufacture resulting in the 3D printing of novel ceramic composites. Additive manufacture or 3D printing of bulk ceramic and ceramic composite components occurs at considerably lower temperatures and shorter manufacturing intervals than the current state of the art. The methods, processes, systems, devices and apparatus and selection of precursor resins produce ceramic and ceramic composite material systems which have not been produced before by 3D printing.

Additive manufacturing 3D printing of advanced ceramics

Methods for producing Polymer Derived Ceramic (PDCs) particles and bulk ceramic components and compositions from partially cured gelatinous polymer ceramic precursors and unique bulk composite PDC ceramics and unique PDC ceramic particles in size and composition. Methods of making fully dense PDCs over approximately 2 &#x3bc;m to approximately 300 mm in diameter for applications such as but not limited to proppants, hybrid ball bearings, catalysts, and the like. Methods can include emulsion processes or spray processes to produce PDCs. The ceramic particles and compositions can be shaped and chemically and materially augmented with enhancement particles in the liquid resin or gelatinous polymeric state before being pyrolyzed into ceramic components. The resulting ceramic components have a very smooth surface and are fully dense, not porous as ceramic components from the sol-gel process.

Methods, processes, and systems for producing bulk ceramics from agglomerations of partially cured gelatinous polymer ceramic precursor resin droplets, without using sponge materials to form gas pathways in the polymer bodies. Ceramics can be formed in hours. Resin droplets can be produced with a sprayer where liquid polymer precursors, mixed with a curing agent, are sprayed forming droplets which are partially cured, collected, and compressed into shapes. Ceramic porosity can be varied, droplet particle sizes can be controlled by adjusting liquid and gas pressure, orifice size, during spraying. Partially cured droplets can be formed via an emulsion process and size controlled by emulsion liquid and surfactant selection parameters.

Method for producing bulk ceramic components from agglomerations of partially cured gelatinous polymer ceramic precursor resin droplets

This invention relates to polymer derived ceramics (PDC's) and more particularly, to methods and product made by using polymeric derived ceramic precursors to synthesize dense, crack-free bulk ceramics in a technique using sacrificial molds, coating processes, replication processes, assembly processes and finishing processes; where gas release paths are created and maintained during these processes to release gases generated during pyrolysis of the ceramic precursor. It is a primary objective of the present invention to provide a well defined method to create PDC voxels which are interconnected as a bulk (high density) material. Such a material is effectively a lattice with face centered cubic or hexagonal close pack geometry. A second objective of the present invention is to provide a method for bulk, high density material to be combined with fully dense material in a hybrid material. A third objective of the present invention is to provide a method for different types of bulk and fully dense materials, and other items (optionally), to be combined in to a composite material.

Methods for synthesizing bulk, composite and hybrid structures from polymeric ceramic precursors as well as other polymeric substances and compounds

A method and product made by using a polymeric ceramic precursor to synthesize dense, crack-free bulk ceramics in a technique using a sacrificial mold provides a ceramic structure for many technical, medical and industrial applications. The novel process uses an open cell material as a sacrificial mold to shape a ceramic precursor during curing. The cured ceramic green body can be machined and shaped to form the desired ceramic structure prior to final pyrolysis. The open cell material forms gas release paths to release large amount of gases generated during the pyrolysis of the cured ceramic precursor. After pyrolysis, an intact, dense, crack-free ceramic structure with high purity, strength and durability is obtained. Uses of the present invention include, but are not limited to, bulk ceramic parts, ceramic crucibles, a replacement material in some applications involving glass, silicon carbides, silicon nitrides, hafnium carbide and the like.

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Orlando, FL, United States of America

Arnold Hill