Improved Composite Fillers

High loadings of particulate, inorganic fillers in organic binders are often desirable for some composite bulk property of interest. The loadings are limited by processing concerns, resultant composite mechanical properties, or both. When high loadings of a filler which bonds poorly (or not at all) to the binder are attemped, the composite strength falls below useful values. New techniques for applying very thin, conformal coatings of organic materials to particulate fillers have been developed and appear to offer a solution to the low bond strength problem. Fillers coated with micron-thin films of excellent quality deposited by Supercritical Fluid-aided (SCF) process techniques are speculated to provide the required interface between particle and binder which will markedly improve bonding. Improved bonding should allow significant increases in particulate loadings without compromising the mechanical properties of the composite. This proposed effort will demonstrate the feasibility of utilizing a SCF-coated inorganic filler in an organic binder above the currently tolerable loading level. Anticipated Benefits: Tactical and Strategic Weapons Space Programs Commodity Bulk Particulate Manufacture and Distribution