WO2009055919A1

WO2009055919A1 - Composite material

Info

Publication number: WO2009055919A1
Application number: PCT/CA2008/001913
Authority: WO
Inventors: Zvonimir Segaric
Original assignee: Zvonimir Segaric
Priority date: 2007-10-30
Filing date: 2008-10-30
Publication date: 2009-05-07

Abstract

A composite material is provided including a plurality of panels. Each panel includes a plurality of evenly spaced hemispherical shells. Each hemispherical shell includes a concave inner surface, a convex outer surface and an annular surface. Each panel further includes a plurality of flanges each extending outwardly from the annular surface of a respective one of the plurality of hemispherical shells. Each flange extends in a direction substantially perpendicular to the convex outer surface, and the flanges extend between adjacent hemispherical shells. The plurality of panels is divided into pairs of panels, the pairs of panels being oriented such that the annular surface of a first of the pair of panels mates with the annular surface of a second of the pair of panels and the concave inner surface of the first of the pair of panels faces the concave inner surface of the second of the pair of panels thereby forming a spherical hollow area therebetween. The pairs of panels are stacked so as to orient the spherical hollow areas in a close- packed formation.

Description

COMPOSITE MATERIAL

Field of the invention:

The present invention relates to building materials and the like. More particularly, and in its preferred intended use, the present invention relates to a cellular material comprising a plurality of spherical hollow areas.

Background of the invention:

The 21st century is a time where more and more people are concerned about the environment, thus recycling renewable materials and manufacturing plastics and other synthetic products with less toxic chemicals. In the construction industry, engineers are designing structures and materials that can resist extreme conditions. The aerospace and naval industries are developing new lighter and stronger materials.

Many examples exist of periodic cellular and foam materials that in both categories have open-cell, partially open-cell and closed-cell structures. There are some aspects of these materials where the topology design can be problematic.

Closed-cell periodic materials such as honeycomb materials and the like are widely used in many categories of engineering for making rigid and lightweight structures. However, they also have disadvantages, such as the limited design options such materials provide. Not only is it very difficult to integrate a gas or an atmospheric pressure into a honeycomb-cored material, but the honeycomb provides mechanical strength in a single direction. Moreover, they are prone to fluid ingression, which can lead to debonding at structural joints.

Open-cell periodic materials in general use hollow tubes, solid wires and expanded metal sheets which al have the same problems. The topological design uses linear segments, can only be manufactured in a panel format and similarly provides mechanical strength in a single direction. These materials are time consuming to produce and are known to have defective weld bonds.

Vacuum panel technologies and all vacuum super insulation panels made of open-cell foams are currently used for highly efficient refrigeration systems, thin insulation capabilities, but they are known to have one major flaw. The panel must be cut in the desired shape and then it's wrapped with panels and other products requiring extreme insulation properties. Despite super insulating a membrane to enclose the vacuum in the panel, if the membrane is punctured, the entire sheet looses its initial R value.

An ultra light weight material such as nano-foam aerogel is gaining popularity in many engineering disciplines. There are numerous advantages related to aerogel and it is still in a developing stage. It can be easily observed that aerogel is brittle and fragile in general even if it's known to have impressive load bearing abilities. One particular field is where vacuum aerogel panels can be produced to have a 90% vacuum and have very low thermal conductivity. By retaining a high vacuum, the aerogel looses its crush resistance capabilities and can collapse on impact.

Metal foams, both closed-cell and open-cell, are mainly used in advanced technology aerospace and manufacturing sectors. The open-cell foams are efficient as thermally resistant filters and closed-cell foams make good impact-absorbing material. On the other hand, metal foams are very expensive, produce toxic by-products when manufactured, are often brittle and have poor structural properties. They are also limited by their stochastic or random structure which limits fluid flow in thermal management.

Dome structures are the most resistant to extreme conditions. There are monolithic domes and geodesic domes, but both have significant problems in the choice of materials. Monolithic domes use spray polyurethane foam, which is toxic and is environmentally unfriendly. Geodesic domes have a long history of problems with water infiltration and wastage of building materials since the materials are sold in a standard rectangular shape rather than the triangular geodesic dome geometry. Concrete buildings and structures are typically created by first building moulds into which concrete, or a similar material, is poured. These moulds, called formwork, use laminated wood materials that are very heavy, making them unpractical and hard on the workers. Traditional formwork using mainly wood results in a lot of waste, when not recycled. Insulated concrete form systems use mainly Styrofoam, which is a highly industrialized material that requires vast amounts of energy to manufacture and is very toxic if it ever burns. Thermal insulation materials such as rock wool are hazardous to health, irritating and useless if not well installed. In addition, countries such as the Netherlands are building houses on water using Styrofoam and concrete which are environmentally unfriendly. Some of the floating foundations of these houses are hollow, which could be catastrophic in the case of a breach.

The frames and internal structures of airplanes and the like are built to be both strong and light. Hollow structures and framework can be problematic if the plane crashes in water and there is a breach on the body since the plane will likely sink, which could result in the loss of the airplane and, moreover, endanger the lives of those on board. Constant checking for micro fissures on the skin is done to prevent disasters and if not constantly checked, the microscopic flaw can result in to a catastrophe.

Boat framework is somewhat similar to airplane framework. When the compartments in a hull structure are interconnected and the hull is breached, the boat will likely sink.

Composite materials and the like, comprising a fibre embedded within a matrix, are known in the art. Modern composite materials utilize fibres made of carbon, glass or aramid fibres bonded within a resin. The resin may be a thermosetting polymer such as an epoxy, or a thermoplastic polymer.

The advantages of such composite materials are also known. Specifically, the choice of fibre and matrix can be made in order to tailor the properties of the composite material. Moreover, composite materials may be formed in moulds, which is advantageous when manufacturing products with curved surfaces.

Known to the Applicant are the following US patents and/or patent applications which describe other composite materials and the like: US 3,316,139, US 3,515,625, US 3,656,317, US 3,769,126, US 4,013,810, US 4,250,136, US 4,588,443, US 4,818,583, US 4,906,518, US 4,919,991 , US 5,100,730, US 5,171 ,346, US 5,251 ,414, US 5,275,854, US 5,310,592, US 5,364,679, US 5,552,215, US 6,261 ,469, US 6,670,046, US 6,868,645, US 6,998,359, US 7,045,195, US 7,232,605, US 2005/0153613 and US 2005/0154087.

It would, however, be desirable to provide an improved material with improved strength, impermeability, impact resistance, structural integrity, which is thermally and/or acoustically insulating as well as lightweight.

Summary of the invention:

An aspect of the present invention is to provide a composite material which, by virtue of its design and components, satisfies some of the above-mentioned needs and is thus an improvement over other related materials known in the prior art.

More particularly, a composite material is provided including a plurality of panels. Each panel includes a plurality of evenly spaced hemispherical shells. Each hemispherical shell includes a concave inner surface, a convex outer surface and an annular surface. Each panel further includes a plurality of flanges each extending outwardly from the annular surface of a respective one of the plurality of hemispherical shells. Each flange extends in a direction substantially perpendicular to the convex outer surface, and the flanges extend between adjacent hemispherical shells. The plurality of panels is divided into pairs of panels, the pairs of panels being oriented such that the annular surface of a first of the pair of panels mates with the annular surface of a second of the pair of panels and the concave inner surface of the first of the pair of panels faces the concave inner surface of the second of the pair of panels thereby forming a spherical hollow area therebetween. The pairs of panels are stacked so as to orient the spherical hollow areas in a close-packed formation.

Preferably, the composite material further comprises a matrix which fills the spaces between the pairs of panels.

Preferably, the composite material further comprises a hexagonal mesh which comprises a plurality of linked hexagonal elements extending around respective hemispherical shells. Preferably, the hexagonal elements are sized to fit a respective one of the plurality of shells.

Preferably, the composite material further comprises a pair of first and second sheets enclosing the matrix and mesh.

According to yet another aspect of the present invention there is provided a composite material including a plurality of perforated hollow spheres which are moulded in a composite material.

As will be appreciated, a composite material according to the present invention is very versatile and can be used in many applications. In addition, it will be appreciated that a composite material according to the present invention comprising panels of hemispherical shells may advantageously ease manufacture and installation.

The invention and its advantages will be better understood by reading the following non- restrictive description of a preferred embodiment thereof, made with reference to the accompanying drawings.

Brief description of the drawings:

The invention will be better understood upon reading the following non-restrictive description of the preferred embodiment thereof, made with reference to the accompanying drawings in which:

FIG. 1 is a partially cut-away isometric view of a layer in accordance with an embodiment of the present invention.

FIG. 2 is a partially cut-away isometric view of a layer in accordance with another embodiment of the present invention.

FIGs. 3a to 3c are a top view of a hexagonal element, an isometric view of a segment and a top view of a three string knot in accordance with an embodiment of the present invention.

FIGs. 4a to 4d are isometric views of meshes in accordance with an embodiment of the present invention.

FIG. 5 is an exploded view of layers in a hexagonal close packing formation and a face centered cubic packing formation.

FIG. 6 is an isometric view of an upper portion of a composite material in accordance with an embodiment of the present invention.

FIG. 7 is an isometric view of a composite material in accordance with another embodiment of the present invention.

FIG. 8 is an isometric view of a composite material in accordance with the embodiment of FIG. 6.

While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the appended claims. Detailed description of preferred embodiments of the invention:

In the following description, the same numerical references refer to similar elements. The embodiments shown in the figures are preferred, for exemplification purposes only.

In addition, although the preferred embodiments of the present invention as illustrated in the accompanying drawings comprise various components, etc., and although the preferred embodiments of the composite material and corresponding parts of the present invention as shown consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present invention. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperations therebetween, as well as other suitable geometrical configurations may be used for the composite material according to the present invention, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art, without departing from the scope of the invention.

Within a periodic cellular structure, that is one comprising individual cells which repeat throughout the structure, formed form a plurality of spherical cells, those spheres can be placed in various geometric configurations, for example: hexagonal close packing formation, a face centered cubic packing formation, or a mix of the two.

With reference now to FIG. 1 , a sphere shell panel 10 is composed of a plurality of adjacent hemispherical shells 12. Each shell 12 comprises a concave inner surface 16, a convex outer surface 17 and an annular surface 15. A flange 11 extends perpendicularly outward from the annular surface 15 and links a given shell 12 to its neighbours. The hemispherical shells 12 of a given panel 10 are evenly spaced across the panel 10 and aligned so as to open in the same direction. In the embodiment shown in FIG. 1 , a first panel 10 comprising a set of upward facing shells 12 is shown underneath a second panel 10 comprising a set of downward facing shells 12.

Pairs of facing panels 10 form a layer 20 comprising a plurality of spherical hollow areas 22 between corresponding upper and lower shells 12. The panels 10 may be bonded together along their respective flanges 11. In use, a composite material 50 (see FIGs. 6 to 8) is created by stacking a plurality layers 20 one on top of another and filling the spaces therebetween with a matrix. Preferably, a fibre mesh 28 is provided between the shells 12. Preferably for practical handling, all meshes are impregnated by a resin, then cured and then cut in to the desired shape before being assembled with the rest of chosen elements.

An opening 14 is provided between any three adjacent shells 12 in order to let a matrix and/fibre penetrate therethrough. The embodiment illustrated in FIG. 1 comprises corners triangular shaped openings 14 with rounded , although it will be appreciated that alternatively shaped openings, such as a circular opening 14, is well within the scope of the present invention.

Preferably, the outer diameter of the hemispherical shell 12 is approximately 20mm, although smaller or larger hemispherical shells 12 are well within the scope of the present invention. The thickness of the sphere shell through the inner and outer hemispheres 16 and 17 may be tailored for the specific end use.

For clarity, the first and second panels 10 have been illustrated comprising four shells 12 and two shells 12, respectively, although it will be appreciated that the panels 10 could be extended in either direction and each comprise any number of individual shells. For example, for larger diameter shells 12, in the range of 200mm and 1m in diameter, four- sphere panels may be preferable, while smaller diameter panels may comprise many more. Moreover, the shells 12 which make up a given panel 10 may be arranged in various forms depending on the desired usage. In the close-packed alignment illustrated, the shells form roughly a parallelogram. This shape could be continued for larger numbers of shells, although a rectangle or square could also be roughly approximated.

Given multiple layers 20 stacked one atop another in a close-packed formation, each hemispherical shell 12 within a panel can engage a total of six neighbouring shells 12. Those shells situated along a side of the panel, and which therefore engage less than six neighbouring shells 12, will further comprise an edge 13 along the outside of its flange 11 where another shell 12 could be. These straight edges 13 facilitate the alignment with another shell 12 of an adjacent panel 10.

It will be appreciated that a plurality of individual shells 12 provided, each with six edges 13 and therefore unattached to any adjacent shells 12, could be aligned individually to form panels 10 and layers 20.

A composite material 50 formed by combining many layers 20, not just stacked one atop another, but aligned side by side, may include layers 20 of spheres having an elongated parallelogram shape, for example a panel of six by eighteen shells 12. Such layers 20 will have four sides along which they engage adjacent layers 20. It is preferable that the seam created between two side-by-side layers 20 along their edges 13 do not overlap an equivalent seam between layers 20 stacked either thereabove or therebelow. These seams may be laterally/transversely staggered, or may be at an angle with respect to one another. Such a non-overlapping arrangement is preferable in order to assure the structural integrity of the overall composite material 50.

The spherical hollow area 22 created between two facing hemispherical shells 12 can be filled or emptied according to the desired application. For example, in one embodiment a spherical block of aerogel, having a diameter equal to that of the inner surface 16, could be sandwiched between shells 12. During the assembly of the panels 10, aerogel spheres are bonded to the inner hemisphere 16 of one of the half sphere shells 12 with an suitable adhesive, where the other half is later bonded to enclose the desired atmosphere in the aerogel spheres. The preferred internal atmospheres would be a vacuum and/or saturated with helium. The use of aerogel spheres would provide an increased crush resistance while in the same time being as light as possible. Just as well, styrofoam spheres or aerogel spheres in the hollow spheres panels will enable the material to be impervious to water infiltration and add strength. While on the opposite extreme, solid metal spheres located with a 3 dimensional mesh can be used to make blast-proof and booklet-proof composite material.

Since the composite material can be used in many applications, there is a wide variety of primary materials that can be used to make the sphere shell panels 10 so it can meet the desired requirements for the end use. In resent years there is a lot of development of nano-composites and bio-composites that the present invention may benefit from. Here are only a few examples of primary materials that are going to be used.

Mineral fibres such as fibreglass, silica filament or better yet, basalt fibres can be used to make the sphere shell panels 10. Basalt fibres mixed with 20-24% polymer binding have high-temperature insulation applications and is best suited as a reinforcement for concrete due to its tensile strength and natural resistance to deterioration from alkali, it is also used as a reinforcement for composites, polyester/epoxy resins and plastics as used in automotive body panels, boat hulls, pultruded products and the like.

Carbon based fibres such as bucky balls, helium bucky balls, carbon fibres, carbon nano tubes and bucky paper can be used. Where for example a combination of fullerene nano tubes with polyvinyl alcohol (PVA) would be used fore the ultra light composite version. The larger sphere shell panels 10 can be made of fibre reinforced ceramic matrix composites to build waterproof and long lasting structures.

Organic fibres such as nano paper, feather fibres, hemp, kenaf, flax can also be used. Cellulose fibres can be bound without an adhesive by using the zelfo method. Cellulose nano crystal reinforced plastic, all-cellulose composite, cellulose nano composites cellulose "whiskers" may all also be considered since they offer useful mechanical properties and are readily obtained from renewable biosources such as wood and cotton. Alternatively, this embodiment can be made of hemp fibres mixed with a soy protein based adhesive that will give the present invention strong, light, water resistant, eco friendly and cost effective qualities. It will be appreciated that many suitable synthetic fibres may also be used.

The panels 10 can be made of fibre reinforced plastics such as polyimide plastic, cellulose nano crystal reinforced polymers, thermoplastics reinforced with cellulose nano crystals, and Kevlar.

Preferably, the materials used are 100% environmentally friendly.

When the two halves of the sphere shell panels 10 are to be bonded, a particular atmosphere for a specific use can be retained and hermetically sealed within the fully assembled layer 20. As this technology is very versatile, it is operable to be used in many different environments. Adapting the atmosphere inside the spherical hollow areas 22 for the specific uses and exterior environments will maximize the efficiency of the material. The manufacturing process to retain the desired internal atmosphere in the spheres will be made in a hermetically closed chamber.

For example, ambient air within the spherical hollow areas 22 would be the simplest to manufacture and most likely to be used.

However, the spherical hollow areas 22 may be provided which retain the air we breathe at a pressure which is less that atmospheric pressure. The internal atmospheric pressure in the spheres can be tuned to equal the atmospheric pressure of the environment where it will be used. A vacuum, or as close thereto as possible, inside the sphere shell panels 10 will give a thermos effect, thus having thermal insulation properties if the negative pressure is strong enough without collapsing the shells 12, unless aerogel spheres are used. Also, a lower pressure within the sphere shell panels 10 would also aid in soundproofing as the thinner atmosphere will reduce sound's ability to travel therein. Such panels 10 are preferably not used for structural purposes, since the shells 12 could collapse on impact. Similarly, sphere shell panels 10 may be provided having an internal atmospheric pressure which is above regular pressure. Such a high pressure sphere could be used, for example, in under water applications where the pressure of the water is much greater than that above the surface.

Sphere shell panels 10 that retain argon gas at a desired atmospheric pressure are also possible. These sphere shell panels 10 can be used for insulation. Their R-value is dependent on the by the number of layers of the argon spheres used. The argon spheres can be used for structural purposes, since the atmospheric pressure will be the same as the atmospheric pressure of the surrounding environment.

Helium filled panels 10 would retain helium gas at a desired atmospheric pressure. These spheres are applicable in the aeronautical industry and to build any structure that needs to be lightweight.

With reference now to FIGs. 3a to 3c, a woven hexagonal mesh 28, or netting, having a hexagonal pattern is illustrated. In an embodiment of the present invention, a mesh 28 is be utilized within a composite material to at once strengthen the material and further restrain spheres formed by the panels 10 in a tight, compact and orderly arrangement. However, it will be appreciated that the hexagonal mesh 28 alone can be used in many applications that are not in relation to the present technology.

The hexagonal mesh 28 is may be formed in a suitable weaving pattern or other appropriate alternative. The hexagonal mesh 28 comprises six hexagonal segments 29 separated by six joints 30. Each joint 30 connects three segments 29, as the hexagonal pattern repeats itself. The strings can be made of any of the fibres mentioned above. For example, hemp string is preferably used for general purposes. For extreme purposes, spider silk or carbon fibre may be used.

In use, it may be advantageous to link a hexagonal mesh 28 to another such hexagonal mesh 28 in order to form a 3-dimensional mesh 28. A perpendicular triple helix, shown in FIG. 3a linking segment 31 is provided to connect two parallel woven meshes 28 by extending between their respective joints 30. In the illustrated embodiment, there is one complete linking segment 31 and a sectioned linking segment 31 where both are in a face centered cubic packing formation.

The triple helix linking segment 31 is started with a three-string knot 32 as illustrated in FIG. 3c. The extremity 34 of each fibre 33 is secured while the rest of the fibre 33 is used to make the knot 32. The knot 32 is placed below the junction 30 and the fibres 33 are wrapped therearound, between the outstretched segments 29. The fibres 33 are then twisted in a helical manner forming the triple helix linking segment 31. Once the desired height is attained, the strings 33 are ready to enclose the next hexagonal mesh 28.

The linking segment 31 may be ended after being secured to the next hexagonal mesh 28, or may be continued in order to link additional meshes 28. Preferably, the linking segment 31 is double-knotted at its start and finish.

With reference to FIGs. 4a to 4d, FIG. 5 and FIG. 6, numerous embodiments of the single layer mesh 28 and linked 3 dimensional mesh 28 are possible in order to reinforce and/or restrain a plurality of sphere shell panels 10 within, for example, a composite material. Although numerous configurations are possible and within the scope of the present invention, there are four embodiments in particular which are described herein.

The first embodiment, shown in FIG. 4a, comprises a pair of hexagonal meshes 28 between which a sphere formed by a pair of shells 12 may be constrained. The hexagonal mesh 28 is sized such that hexagonal segments 29 surround the sphere shells 12 tightly.

The second embodiment is illustrated in FIG. 4b and comprises two hexagonal meshes 28, three linking segments 31 twisted between two hexagonal meshes 28 for binding one layer of sphere shell panels 10 and followed by six sectioned linking segments 36 which extend upwards and downwards from each of the three segments 31. This variation is used in the hexagonal close packing formation where this pattern repeats throughout the layers 20 of shell panels 10 and meshes 28. As such, the layers 20 can all be attached by linking members 31 which extend vertically from top to bottom.

Similarly, the third embodiment is illustrated in FIG. 4c and comprises two hexagonal meshes 28, six linking segments 31 wrapped between two hexagonal meshes 28 that bind one layer 20 and six sectioned linking segments 36. The sectioned linking segments 36 are positioned in an alternating manner showing the continuation of the linking segments 31 that bind two layers of sphere shell panels 10 and 11 and so is the knot 32 the end of the linking segments 31. This variation is used in the face centered cubic packing formation, where all linking segments 31 attach a total of four hexagonal meshes 28, thus attaching two layers 20 of sphere shell panels 10.

The fourth embodiment is illustrated in FIG. 4d and comprises two hexagonal meshes 28, six linking segments 31 twisted between the hexagonal meshes 28 and followed by twelve sectioned linking segments 36 that show the continuation of the linking segments 31. In this particular variation, the linking segments 31 may vary in length to tailor the density of the 3D mesh 28.

This 3 dimensional mesh 28 with the linking members 31 is further shown in FIG. 5, which provides an explanatory exploded view. The layers 20a to 2Od illustrate two distinct packing formations. Specifically, the layers 20a to 20c form a hexagonal close packing formation when unexploded. The layers, 20b to 2Od form a face centered cubic packing formation. As will be apparent, the mixture of hexagonal close packing and face centered cubic packing formations created by combining all four layers 20a to 2Od could also be used if desired. Each layer 20 is linked by sectioned linking segments 36, although it will be appreciated that these linking segments 36 are continuous with respective linking members 31. Due to the close-packed formation of the shells 12, a given hexagonal mesh 28 will overlap a parallel hexagonal mesh 28 immediately above or below at three of its six joints 30. The remaining three joints 30 are aligned with the center of another shell 12 in the upper and lower layers 20.

As discussed above with regard to the seams created between side-by-side layers 20, it is similarly possible that two or more sections of hexagonal mesh 28 be positioned side- by-side and that a seam is created therebetween. It is similarly preferable that the seams formed in parallel layers are also translated or rotated with respect to one another, i.e. that such seams similarly do not overlap. Moreover, it is preferable that the seams within a layer 20 of panels 10 do not overlap the seams within adjacent layers of mesh 28.

With reference now to FIG. 6, an uppermost layer 20 is illustrated with two tri-axial supplemental meshes 40 and 42. The fibre of these supplemental meshes 40 and 42 is about the same diameter as the fibre 33 from the hexagonal mesh 28, while the fibre of the supplemental mesh 42 is approximately twice the diameter of the fibre 33. Alternatively, the supplemental meshes 40 and 42 can also be of the same diameter. The supplemental mesh 40 fills the space between the upper sphere shell panel 10 and a sheet 44 which forms the outside of the composite material 50. Preferably, the sheet 25 comprises a single or multiple layers woven fibre. More preferably, the sheet 44 is woven of hemp fibre or, in more demanding applications and environments, carbon fibre. In production, all layers can be soaked in epoxy resin.

As discussed above with regards to the seams created between side-by-side layers 20 and side-by-side sections of mesh 28, it is similarly possible that two of more sections of the supplemental mesh 40 be positioned side-by-side and that a seam is created therebetween. It is similarly preferable that the seams formed in parallel layers are also translated or rotated with respect to one another such that no seams overlap.

Preferably a matrix is provided for bonding the panels 10 and meshes 28, 40 and 42 together. The matrix would then also fill the remaining space between the sheets 44. As is known in the art, the matrix may be selected from any of a variety of applicable materials such as thermosetting polyester resins, cellulose solutions or papercrete.

Depending of the specific fibres used, the choice of adhesives will be chosen accordingly. To fill the voids between the hollow spheres, which are about 26% volume, there are a number of different fillers that can be used to strengthen and lighten the matrix mix. Helium saturated carbon aerogels and carbon aerogels represent low density solids available on the market and can be produced, powders, monoliths, or micro spheres.

Preferably, there will be an environmentally friendly fire-retardant epoxy resin or ordinary epoxy resin mixed with other ingredients making it stronger and lighter. Further elements may be added to the composite material 50 in accordance with its specific use. The following combinations are listed for exemplification but should in no way be considered limiting: a mix containing 50% of micro fibres (leftover fibre, for example hemp string or feather fibre, chopped in pieces) and 50% epoxy resin; a mix containing 30% of micro fibres, 30% micro glass spheres and 30% epoxy resin; a mix containing 50% micro glass spheres and 50% epoxy resin; a mix containing 50% compressed gas bubbles and 50% epoxy resin.

For ultra light application, 70% helium saturated glass micro spheres or aerogel powder, 15-20% adhesive, and 15-10% nano tubes could be used. For large floating structures: 60% concrete, 20% expanded clay aggregates, 10% micro spheres, 10% basalt fibres would provide high amounts of buoyancy. For example, larger sphere shell panels 10 in the range of 1 meter in diameter made of a fibre reinforced ceramic matrix composite that are additionally reinforced by a 3 dimensional mesh 28 made of basalt fibres and further more reinforced by a matrix mix containing 60% polymerized concrete, 30% micro spheres and 10% basalt fibres.

With reference now to FIG. 2, an alternate embodiment of the panels 10 of FIG. 1 is shown. A sphere shell panel 10' comprises individual shells 12' which each comprise three flat disc-shaped engagement portions 55 which project outwards from the outer surface 17' and six half-disc engagement portions 57 which project outwards from the outer surface 17' adjacent the flanges 11'. When an upward facing panel 10' and a downward facing panel 10' are joined, pairs of half-disc engagement portions 57 are aligned around the circumference of the shells 12' thereby forming engagement portions around the circumference which are equivalent to the engagement portions 55.

So joined, each shell 12' of a given layer 20' is provided twelve engagement portions 55 and 57 which are aligned so as to engage the twelve adjacent shells 12'. Not only do these engagement portions 55 and 57 provide a larger contact area between stacked layers 20', but they can also be used to bond adjacent shells 12'.

It will be appreciated that the positions of the engagement portions 55 and 57 will vary given the packing formation (hexagonal close packing, face centered cubic, etc). It will also be appreciated that while those illustrated are disc-like in shape, the engagement portions 55 and 57 of the present invention may be provided in a variety of other shapes.

In the embodiment illustrated in FIG. 2, the sphere shell panels 10' are further provided with openings 60 at the center of the engagement portions 55 and 57. These openings provide an open cell structure wherein the spaces within the spherical hollow area 22' are interconnected, thereby creating two separate compartments throughout the volume of the composite material. The space inside the shells 12 consists of about 72% of the total volume and the space outside about 24%. Such interconnected layers 20' could be used as part of a muffler or the like where the exhaust is distributed throughout the spherical hollow areas 22' and a heat exchanging fluid passes around the shells 12' to recuperate wasted heat and reduce sound emissions.

It will be appreciate however that shell panels 10' without the openings 60 would equally be within the scope of the present invention. It will also be appreciated that other openings could be provided in the hemispherical shells 10 or 10' outside of the engagement portions 55 and 57. These perforated, open-cell shells would provide a structural integrity but not isolate the spherical hollow areas 22 or 22' from the remainder of the structure.

With reference now to FIG. 7, a composite material 50 is provided which comprises three layers 20' of the panels 10' illustrated in FIG. 2 positioned in a face centered cubic packing formation. A core of shell panels 10' is sandwiched between two end sheets 44. This particular composite core has more or less than 6% of solid mass per volume. The embodiment of this composite material 50 has excellent thermal exchange qualities where the holes can be in different sizes to control fluid or air flow. Preferably, herein is preferably made from a metal alloy wherein the sphere shell panels 10' are induction welded.

In contrast with the embodiment illustrated in FIG. 6, the uppermost and lowermost panels 10' engage the top and bottom sheets 44 along their respective flanges 11. In this arrangement, the supplemental axial meshes 40 and 42 are not used to fill the area between the sheets 44 and the uppermost and lowermost panels 10'.

With reference now to FIG. 8, a wall section is illustrated. The wall section is formed of a composite material 50 comprising layers 20 of sphere shell panels 10 that are positioned in a hexagonal close packing formation. The sphere shell panels 10 are reinforced and held together by multiple layers of hexagonal meshes 28 that are linked by a plurality of triple helix linking segments 31 forming a 3 dimensional weaving pattern. Between the top and bottom sheets 44 and their respective adjacent layers 20 are positioned the supplemental meshes 40 and 42, as shown in FIG. 6. The sheets 44 are preferably resin-impregnated woven fibre sheets. Through out the wall section there is a matrix 52 that binds all the components mentioned above. This particular composite core has more or less than 18% of solid mass per volume.

An ultra light core may equally be provided wherein sphere shells 10 of different sizes are combined in a single material 50. For example, given two sets of spheres wherein the first set is ten times larger than the second and one or both sets of spheres are filed by an aerogel spheres that are reinforced and held together by multiple layers of hexagonal meshes 28 and a plurality of triple helix linking segment 31. In order to further reduce the mass, the matrix is impregnated with microspheres or crushed aerogel. This particular composite core has more or less than 3% of solid mass per volume.

In the construction industry and the residential sector, a composite material 50 in accordance with the present invention is structural and could replace wood or steel framing. The ability to prefabricate panel shapes lends itself to houses and the like which can be built from prefabricated structural insulated panels and assembled on site. PVC piping can be integrated in the wall panels for electric cables and pluming. The exterior walls can comprise spheres filled with an insulating gas, such as argon. The efficiency of the composite material's insulation, i.e. its R-value, will be dependent on the thickness of the wall.

The strength, lightweight and impermeability of a composite material 50 in accordance with the present invention make it applicable to use in formwork applications. There is also a permanent version of the formwork system that could be prefabricated, somewhat resembling and insulated concrete form systems, with the benefit that it can be fabricated in a variety of shapes.

Claims

1. A composite material comprising: a) a plurality of panels, each panel comprising: i) a plurality of evenly spaced hemispherical shells, each hemispherical shell comprising a concave inner surface, a convex outer surface and an annular surface; and ii) a plurality of flanges each extending outwardly from the annular surface of a respective one of the plurality of hemispherical shells, each flange extending in a direction substantially perpendicular to the convex outer surface, the flanges extending between adjacent hemispherical shells; wherein the plurality of panels is divided into pairs of panels, the pairs of panels being oriented such that the annular surface of a first of the pair of panels mates with the annular surface of a second of the pair of panels and the concave inner surface of the first of the pair of panels faces the concave inner surface of the second of the pair of panels thereby forming a spherical hollow area therebetween; wherein the pairs of panels are stacked so as to orient the spherical hollow areas in a close-packed formation.

2. The composite material of claim 1 , further comprising a matrix which fills the spaces between the pairs of panels.

3. The composite material of claim 2, further comprising a hexagonal mesh which comprises a plurality of linked hexagonal elements extending around respective hemispherical shells.

4. The composite material of claim 3, wherein the hexagonal mesh further comprises a plurality of linking segments which link parallel hexagonal meshes and extend perpendicularly thereto, wherein the plurality of flanges comprises a plurality of openings for allowing the linking segments to pass therethrough. linking

5. The composite material of claim 4, wherein the segments comprise a triple helix structure which is wrapped around the hexagonal meshes.

6. The composite material of claim 2, wherein the plurality of panels comprises an end panel and the composite material further comprises sheet which extends across the end panel.

7. The composite material of claim 6, further comprising a supplemental mesh between the end panel and the sheet.

8. The composite material of claim 1 , wherein each of the hemispherical shells further comprise an engagement portion projecting outward from the convex outer surface for engaging another of the hemispherical shells. portions

9. The composite material of claim 8, wherein the engagement comprise an opening for linking the spherical hollows of adjacent hemispherical shells

10. The composite material of claim 1 , wherein the pairs of panels are stacked so as to orient the spherical hollows in a hexagonal close packing formation.

11. The composite material of claim 1 , wherein the pairs of panels are stacked so as to orient the spherical hollows in a face centered cubic packing formation.

12. The composite material of claim 1 , wherein each hemispherical shell is surrounded by a respective one of the plurality of flanges, wherein each flange comprises an edge for engaging a corresponding edge of an adjacent hemispherical shell.

13. The composite material of claim 1 , wherein the spherical hollow areas are filled with a gas selected from the group consisting of air at atmospheric pressure, air at a pressure less than atmospheric pressure, and helium.