Moldable, High-strength, Low-Temperature Cure, High-Temperature Resistant Composite

Invention Summary: Ceramic composites are popular in applications where materials are expected to encounter high temperatures, i.e. engine components, exhaust systems, and fire barriers. The low density as compared to metals makes them attractive in applications where weight is a critical design parameter. However, most ceramic composites are fabricated using high heat treatment and the operating temperatures are often lower than the temperatures used for the fabrication of the composites. In addition, the production of high-temperature resistant ceramic composites typically involves the use of expensive high-temperature equipment and exotic starting materials. The co-director of Rutgers Structures and Advanced Materials program has developed a new patent pending “Moldable, Low-temperature Cure, High-temperature Resistant” inorganic composite material The material can be used as a coating over various substrates, or molded into different forms. The invention is directed to a method for preparing, and composition of matter of, a high-temperature heat-resistant composite material by combining a mixture of submicron alumina and silica powders along with submicron Group II metal oxide powder, and a Group I metal silicate solution to form a slurry. The addition of contacting reinforcing high-temperature resistant fibers with the slurry forms a composite precursor composition; and curing the composition at a low temperature is sufficient to produce the high-temperature heat-resistant composite material capable of resisting temperatures to over 2500° F. Market Applications: The composite material has a wide variety of applications where a high strength and fire resistant material is needed; two such applications are structural rehabilitation of bridges, and protective coatings on concrete, steel, brick, and wood structures. Advantages: Material can be molded into different forms, or used as a coating Material possesses all the advantages of the current Fiber Reinforced Polymers High temperature resistance of over 2500° F Low-to-room temperature curing process Non-toxic and no VOC during mixing, application, curing, or during its life cycle with no smoke or fumes if exposed to fire Excellent bonding to concrete, steel, brick, wood, and stone Intellectual Property & Development Status: The coating has been applied and tested on bridge and other structures in New Jersey, Maryland, and Rhode Island with successful results. Self cleaning properties are being assessed. Patents pending for composition of matter and process for making the composite material.