Patent ID: 8470112
Filing Date: 2013-06-25
Classification: B01J,B28B,B32B,B82Y,C23C,Y10T

Abstract:
1. A method of making a composite material, the method comprising: providing a tile, wherein the tile comprises an inorganic material; and bonding the tile to a ductile backing material using heat-curable adhering material and catalyzed foamable exothermic material between the tile and the ductile backing material, wherein heat generated from the use of the catalyzed foamable exothermic material cures the heat-curable adhering material; wherein the step of bonding comprises: wetting an interior surface of the tile with the heat-curable adhering material; wetting an interior surface of the ductile backing material with the heat-curable adhering material; forming an interior volume between the tile and the ductile backing material, wherein the interior surface of the tile and the interior surface of the ductile backing material are facing one another, and wherein the interior surface of the tile and the interior surface of the ductile backing material each form a boundary of the interior volume; inserting the catalyzed foamable exothermic material into the interior volume after wetting the interior surfaces of the tile and the ductile backing material with the heat-curable adhering material, wherein an amount of catalyzed foamable exothermic material is used that is sufficient to fill the entire interior volume when foamed and form a solid foam body between the tile and the ductile backing material; and allowing the exotherm from the foaming to activate and cure the heat-curable adhering material for a time sufficient to unite the solid foam body to the heat-curable adhering material of the tile and the ductile backing material.