Processing and Characterization of Ultralow-Binder-Content Particulate Composites

We developed the technique of compaction self-assembly (CSA), through which ultralow-binder-content (UBC) particulate composites were produced, with the binder content (c) in the range from 2 to 8 wt.%. In CSA, a high pressure is applied on premixed binder and granular filler, so that the material is densified and the binder is self-assembled into polymer micro-agglomerations (PMA) at critical load-carrying locations. Such a microstructure minimizes the system redundancy. The flexural strength of the UBC composite is ~25 MPa and the compressive strength is more than 50 MPa. This technology may find important applications for advanced pharmaceutical manufacturing, green cement, energy storage materials, among others.