CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 62/443,388, filed January 6, 2017, the disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] Transparent ceramics (also known as "Transparent Aluminum") include but are not limited to materials such as aluminum oxynitride. Aluminum oxynitride (or "AION") is a ceramic powder made of aluminum, oxygen, and nitrogen. In the visible spectrum, AION is optically transparent. Additionally, AION is one of the hardest and strongest polycrystalline transparent ceramics available today. The transparent nature of the ceramic, combined with its enormous strength makes it a desirable material for use in high-impact environments, such as in military and law enforcement applications. Specifically, AION has been used in bulletproof and blast-resistant windows and in military infrared optics.

[0003] Because AION is a ceramic powder, it can be fabricated in many different shapes, including but not limited to windows, plates, domes, rods, tubes, etc. using conventional ceramic powder processing techniques. This makes the material very attractive to many different industries beyond the military. Unfortunately, however, the material can be extremely costly to manufacture in large quantities, and the expansion into other industries has been slow.

[0004] As research continues to evolve, making the manufacture of AION more cost effective, it may become increasingly implemented as a building material because of its many benefits. It would be advantageous for an AION construction material (or composition) to be further configured for implementation into a controlled response system for reducing the effects of impacts on a surface comprising the AION composition.

SUMMARY

[0005] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. It is not intended to identify the critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented herein. [0006] In one embodiment, a particle includes an outer shell having an outer surface and an inner surface forming a hollow core; and a response unit housed inside the hollow core. The outer shell comprises aluminum oxynitride.

[0007] In another embodiment, a system for sensing and providing a controlled response to changes in a particle environment, includes a particle having an outer shell and a hollow inner core, and a response unit housed inside the hollow inner core. An external excitation source activates the response unit.

[0008] In still another embodiment, a system for sensing and providing a controlled response to changes in a particle environment includes a particle having an outer shell and a hollow inner core, and a response unit housed inside the hollow inner core; an external excitation source; and a sensor. The response unit is activated by the external excitation source, which causes an ascertainable reaction by the response unit, and the sensor senses the reaction. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0009] Illustrative embodiments of the invention are described in detail below with reference to the attached figures, wherein:

[0010] FIG. 1 is a schematic illustration of a bead according to an embodiment of the invention;

[0011] FIG. 2 is a schematic illustration of a carrier incorporating a plurality of beads of FIG. 1 ;

[0012] FIG. 3 is a schematic illustration of a carrier incorporating a plurality of beads of FIG. 1 as a conformal coating on a surface;

[0013] FIG. 4 A is a schematic illustration of a carrier incorporating a plurality of beads of FIG. 1 disposed between two panels; and

[0014] FIG. 4B is a schematic illustration of the two panels of FIG. 4 receiving a force causing compression of the carrier.

DETAILED DESCRIPTION

[0015] Specially formed damping particles may be implemented into various compositions and/or construction materials, as described in U.S. Patent Application Nos. 15/365,923 and 15/678,392. Such implementation of damping particles into a composition or a material may allow the composition or material to resist breakage, and even to respond to impacts received by composition or material. In embodiments, the particles may be tunable based on the resonant frequency of the impact, such that the impact does not have a lasting effect on the composition or material. Sensors may be deployed at or near the composition or material to gather detailed information about the impact(s), such as the frequency and amplitude of the impact, and this information may in turn be used in tuning the particles. In some embodiments, the particles may be multi-modal. In other words, some of the particles may act to dampen the effects of an impact, while some others of the particles may have sensory capabilities. Here, it may be unnecessary for the composition or material to have separate sensors deployed at or near the composition or material, because the particles themselves may be capable of providing all of the sensory data needed for tuning. Regardless of where the sensor is located, however, information from the material may be sensed in real time, and the particles may be adjusted accordingly. Effects of impacts (e.g., movement, sound, etc.) can thus be reduced.

[0016] It is clear that many benefits can be recognized by incorporating the particles having superior damping effects into a material or composition. The ability of the particles to expand and compress, or to be tuned according to a known resonant frequency, allows the material or composition to readily adapt to changes in its environment. Generally speaking, incorporating the particles into a particular material or composition makes the material or composition act more elastic. However, in embodiments, it may be desirable for a particular material or composition to have increased strength without the need for certain elastic properties, but to still be able to sense attributes related to its environment in order to provide a controlled response.

[0017] In one embodiment of the invention, AION beads are formed which have locale and/or remote sensing and controlled response capabilities, as will be described in greater detail herein. It shall be understood by those of skill in the art that the beads described herein can be incorporated into any number of various materials and/or compositions, and that the examples provided herein are therefore not limiting. The beads described herein exploit the benefits of AION, specifically the strength, formability, and the unique transparent nature of the material, while providing a unique and novel way to sense environmental changes and provide a quantifiable response in reaction to said environmental changes. The beads may range in scale from nano to macro, and anywhere between.

[0018] Referring now to FIG. 1, according to an embodiment of the invention, a bead 100 includes a shell 102 having an outer shell surface 105 and an inner shell surface 110. A void 115 is formed within the inner shell surface 110. A response unit 200 may be situated within the void 115 to provide the bead 100 with the various capabilities that is described herein. The bead shell 102 may preferably be constructed of aluminum oxynitride such that the bead 100 is transparent in the visible electromagnetic spectrum. The bead 100 is shown in FIG. 1 as being spherical in nature. However, it shall be understood that the bead 100 can be any shape that can be formed by AION, including buckyball-shaped, spherical, cubical, rod- shaped, planar, concave, convex, etc.

[0019] The response unit 200 may include one or more controlled response elements 202 which may be electronic, electromagnetic, chemical, electrochemical, mechanical and/or electromechanical elements and may be passive or dynamic in operation. An external excitation may initiate a response by the controlled response element 202, which may be some measurable change in the bead 100 (e.g., vibration, sound, light, temperature, etc.). According to one example, the controlled response element 202 is one or more chemical compounds that changes phase or properties in response to an external excitation. In another example, the controlled response element 202 is a piezoelectric crystal. As is known to those of skill in the art, the piezoelectric crystal can convert electrical energy into mechanical movement, or vice versa, in a controlled response to an external excitation. In some embodiments, the response unit 200 may be a sensor (e.g., camera, video recorder, solar cell, energy harvesting device, etc.) which is embedded within the bead 100. The AION coating provides both electrical isolation and a protective outer layer to prevent harm to the sensors. Because the AION is transparent, the sensor has unobstructed visibility through the encapsulation. Accordingly, cameras and other optical devices may be industrially hardened. These beads 100 may then be embedded into other transparent materials such as windows, glass, polycarbonate, circuit boards, body parts, etc. to provide sensing capabilities to these materials, as is discussed in greater detail below. Accordingly, the beads 100 are capable of both adding strength and controlled action to the environment in which the beads 100 are located.

[0020] Additional benefits, including electrical insulation provided by the encapsulation of response unit 200 within beads 100, may also be recognized. Electrical isolation of sensors can provide safety protection to sensitive electronic components embedded within beads 100 (e.g., as part of the response unit 200) as well as allow operation in high voltage or field-strength environments. Furthermore, the AION ceramic properties can be utilized electrically as a ceramic plate capacitor or ceramic resonator between multiple bead 100 elements. Applications include laser stimulated excitation sensors that are powered, instructed, and accessed through a single beam of light. Other embodiments may include capacitive energy storage devices that utilize the insulating ceramic shells of beads 100 elements to store energy in repeatable charge and discharge cycles effectively creating a transparent battery.

[0021] The beads 100 may be incorporated into a variety of different environments to form a superiorly robust sensing and control system. In a first embodiment, illustrated in FIG. 2, a plurality of beads 100 are distributed throughout a carrier 300. The carrier 300 can be any substance or composition capable of having the beads mixed therein. In embodiments, the carrier 300 is configured as a conformal coating capable of covering an assortment of different surfaces and/or materials. Often conformal coatings are used in the electronics industry to prevent damage to circuit boards and other electronic components. However, conformal coatings may be used in other industries as well, especially for any surface where it would be desirable to prevent corrosion or other damage to the surface. For example, it may be desirable for a section of metal ground pipe to be coated in a conformal coating which may prevent the pipe from rusting.

[0022] As is known to those of skill in the art, there are a number of different conformal coatings that are readily available on the market. A conformal coating may be solvent or water-based, and in some embodiments may require UV curing. The coating may be acrylic, urethane, silicone, or vamish-based. It shall be understood that all chemistries of conformal coatings, whether now known or later developed, are contemplated within the scope of the invention. In embodiments, it may be desirable for the coating material to cure transparent or substantially transparent such that a user can see through the coating. Once the conformal coating material is selected, the beads 100 may be mixed into the coating material before it is applied to the surface. In embodiments, the mixing may occur by the user, whereby the user acquires the beads 100 separately from the coating material. In other embodiments, the coating may be purchased by a user with the beads 100 already distributed therethrough. Regardless, the coating may be applied according to methods known to those of skill in the art. Once the coating is applied to the surface, it is allowed to cure depending on the requirements of the specific coating material. The beads 100 in the coating may result in a coating with an additional layer of physical strength which may be added to the surface receiving the coating. At the same time, the beads 100 may provide sensing and response capabilities as described herein. [0023] As discussed briefly above, the coating may be utilized, for example, as a coating for a ground pipe 400 (FIG. 3). The coating may be applied to the outside of the pipe 400 and allowed to cure. The strength of the AION beads 100 distributed throughout the coating 300 may help to prevent punctures in the pipe 400. Where an impact with the pipe 400 may otherwise result in a puncture, the beads 100 may prevent such distress. Additionally, the beads 100 may be able to provide environmental information about the health of the pipe 400 and/or the pipe contents. For example, once the coating 300 is applied to the pipe 400, the coating 300 may be tuned to a particular resonant frequency which may signify that the pipe 400 is "healthy" (e.g., does not have significant weak spots which may result in rupture). When the pipe 400 is empty, an external excitation source (e.g., a laser or any other external excitation source) can "ping" the pipe 400 at one or more locations. The excitation may cause the response unit 200 inside the bead 100 to resonate. Sensors located at or near the coated surface may receive the frequency of the response, which may be compared against the known resonant frequency for a healthy pipe. If the frequency of the response is within a certain range, the user may know that the pipe 400 is healthy in the location of the excitation. On the other hand, if the frequency of the response is outside the range, then the user may know that the pipe 400 has a weak spot or potential puncture.

[0024] Attributes of the contents of the pipe 400 may additionally or alternately be ascertained based on similar methods. The response frequency of a pipe section 400 that is filled to ½ capacity may be different than a pipe section 400 filled to ¾ capacity. Accordingly, it may be possible to determine how much liquid is in a pipe section 400 simply by providing an external stimulus to the coating 300.

[0025] In determining specific characteristics of the pipe 400 itself, or the contents of the pipe 400, the beads 100 may be functioning in a substantially passive mode. In other words, the beads 100 may simply receive an external excitation which causes the response unit 200 to react. The reaction is sensed by a sensor, and that information can be used to ascertain some characteristic. However, the beads 100 may also (or alternately) function in a substantially active or dynamic mode. Here, the response unit 200 may react in a physical, chemical, or electrical (or electromagnetic or electrochemical) manner that provides a specific change to the coating or the environment. In sticking with the example of a piezoelectric crystal inside the bead 100, the excitation of the crystal as a result of the external stimulus may cause a physical vibration of the crystal. For example, a section of the pipe 400 may receive an external excitation to determine the capacity of the section of the pipe 400. The sensed response to the external excitation may reveal to the user that the section of the pipe 400 being tested appears to have a blockage. In response, the user may provide to the section of the pipe 400 a second external stimulus which may cause the piezoelectric crystals (and therefore the beads 100) to vibrate. This vibration of the beads, which may be imperceptible to the user (e.g., in the subnanometer range) may be sufficient to clear the blockage, thereby allowing the fluid in the pipe 400 to again flow freely. It shall be understood by those of skill in the art that this is merely an example of a controlled response that the beads 100 may give in reaction to an external stimulus. Other controlled responses (e.g., changes in temperature) are further contemplated within the scope of the invention.

[0026] In embodiments, it may be desirable for the coating 300 to be transparent such that a user can view a section of the pipe 400 through the coating. As AION is optically transparent in the visible spectrum, the addition of the beads 100 to the coating 300 does not hamper a user's ability to see through the otherwise transparent coating 300. Here, the coating 300 may be applied as a layered approach to the surface of the pipe 400, each layer providing specific information to the user. For example, flammable liquids may be transported through pipes 400 (or in tanker trucks, containers, etc.), and may become inflamed if the liquid reaches a certain temperature. Here, temperature-sensitive coatings may be applied to the pipe 400 (or other vessel, as the case may be) which may turn colors upon reaching a certain pre-determined temperature. For example, the pipe 400 may include a first layer which is red. A second layer may be applied atop the first layer, which is yellow. The second layer may be configured to become transparent at temperatures above a certain threshold (e.g., 200°F) such that, above the threshold, the first layer is visible. A third layer may be applied atop the second layer, which is green. The third layer may be configured to become transparent at temperatures above a certain threshold (e.g., 150°F) such that, above the threshold, the second layer is visible. The conformal coating 300 having the beads 100 distributed therein may be applied atop the third layer. In this way, a user can see through the conformal coating 300, and be able to tell if the pipe 300 is above a certain predetermined threshold temperature. Specific conformal coating layers may also be capable of fluorescing or producing transmissive (or reflective) wavelengths of light by utilizing components contained within the response units 200, such as LED, oLED, electroluminescent particles, carbon nanotubes, etc.

[0027] In embodiments, it may be preferable for the carrier 300 to be somewhat flexible when cured, such as a gel, foam, caulk, or plastic, for example. The carrier 300 may take the form of an adhesive, or be capable of being adhered to or disposed on a surface. Referring now to FIGs. 4A and 4B, the carrier 300 may be applied between two panels 450. It shall be understood that the panels can but need not be substantially flat and/or parallel. The panels 450 can be manufactured of any material, including but not limited to glass, wood, plastic, etc. When the carrier 300 is applied between the two panels 450, the panels 450 may benefit from the various properties of the carrier material. For example, assume that the carrier 300 is a gel-like adhesive that is applied between the two panels 450. The panels 450 may benefit from the elasticity inherent in the adhesive material in deflecting or damping small forces received by one or more of the panels (e.g., sound waves, etc.). When a larger force is applied to one or more of the panels 450 (represented by F in FIG. 4B), the force may cause the panels 450 to be compressed together. The beads 100, which may otherwise be somewhat regularly distributed throughout the carrier may be forced together as shown in FIG. 4B. The panels 450 however, may be restricted from compressing beyond a certain point, e.g., the distance of the diameter of the bead 100 or stacked beads 100, because the AION material is strong enough to withstand many forces that may be received by such panels 450.

[0028] This may be especially beneficial where it is desirable to ensure that two panels 450 do not compress beyond a certain point. For example, in some situations, it may be undesirable for two plates to come into contact with one another. The beads 100 may be designed to have a diameter that exceeds the minimum allowable distance between the two plates 450. This ensures that the plates 450 do not come into contact with one another. Measurements between the two plates 450 can be made electrically through measured impedance readings between the two plates 450 directly as well as capacitively coupled measurements between a specific plate 450 and a plurality of beads 100 in respect to the other plate 450. For example, if the beads 100 came in direct physical contact with the two plates 450 there would be a definitive reading of capacitance between the two plates via conducting an alternating current through the beads 100 outer shell(s) allowing a measurable conduction path between the two plates 450.

[0029] At the same time, the beads 100 may include a response unit 200 as described herein for providing a controlled response to an external excitation source. Here, the force F received on the panels 450 may excite the response unit 200. A sensor located at or near the panels 450 may sense the spectral response of the response unit 200 as a result of the force F. From the spectral response, a user may be able to determine the health of the panels, the strength of the force F received by the panels, and/or other attributes.

[0030] In one embodiment, the carrier 300 may allow for movement of the beads 100 after the carrier 300 is cured. For example, consider a situation where a carrier fluid 300 (e.g., gas, liquid, gel, etc.) is distributed between two panes of glass surrounded by a frame. The carrier fluid 300 has a plurality of beads 100 dispersed throughout. Here, the response units 200 of a plurality of beads 100 may react in conjunction with one another in order to provide a more focused controlled response. For example, a sensor (which may be a standalone sensor or may be one or more of the response units 200 themselves) may determine that a force is continually hitting one of the panels 450 at a particular location. In response, an external excitation (which may be the force F itself) may cause the beads 100 to congregate near the location where the force is being received. When congregated, the beads 100 may prevent breakage of the window. Or, the sensor may determine a particular wave pattem of a force received upon one of the panels 450 (e.g., sound waves), and may cause the response units 200 to vibrate in an inverse or strategically shaped wave pattem which may attenuate the sound waves travelling through the panel 450.

[0031] In another embodiment, the panels 450 themselves may be constructed directly from AION. Here, a sensor may be distributed at or near one or more of the panels in order to sense changes in or around the environment of the panels 450. The panels 450 may exhibit superior anti-breakage properties. Additionally, due to the transparent nature of the AION, sensors, external excitation means (e.g., lasers), and even users can penetrate or see through the panels 450 in order to measure and/or ascertain changes in the environment of the panels 450. For example, lasers may be directed through the panels 450, and sensors may be able to measure the spectral response of the wave distribution of the laser through the other side of the panels 450.

[0032] In another embodiment, the carrier 300 may be asphalt, concrete, silicone, epoxy, gravel, clay, sand, dirt, etc. The beads 100 may be distributed into the asphalt composition before the asphalt is laid. The beads 100 may cure into the asphalt for providing sensing and controlled response capabilities directly from the surface. Some of the response units 200 of the beads 100 may include piezoelectric elements that can harvest energy (e.g., from the vibrations caused by movement of cars over the roadway, geothermal differential temperatures, etc.). The piezoelectric elements may further allow the beads 100 to provide a controlled response to an external stimulus. For example, a signal sent to the beads 100 in the asphalt may cause the response unit 200 to vibrate or otherwise respond to the stimulus (e.g., change in chemical properties, temperature, shape, radio-frequency transmission, etc.). This may cause an increase in the temperature of the beads 100, which may be used to melt snow or ice accumulated on top of the roadway. The resulting temperature changes (e.g., thermal cycles) may also be selectively initiated and controlled from a remote location in order to repair fractures in the roadways (e.g., micro-fracture repairs within layers of the roadway). Others of the response units 200 may include sensors (e.g., cameras or video recorders) that can view the environment, which information may be communicated to a user (e.g., over a network) for monitoring purposes. As discussed elsewhere herein, the beads 100 may be tuned to a particular resonant frequency such that the health of the asphalt can be monitored through external excitation of the beads 100 and measurement of the spectral response of the external excitation. The beads 100 may be optionally configured, e.g., via the response unit 200, to determine specific locations of vehicles in real-time, act as GPS indicators, and generate and communicate safety alerts. The beads 100 may therefore allow for the real-time monitoring of the roadway for the purpose of extending the life of the roadway and providing efficient and effective road patching and safer, more environmentally conscious road travel.

[0033] Optionally, the carrier 300 may include additional particles, such as the particles described in U. S. Patent Application Nos. 15/365,923 and 15/678,392.

[0034] In still another embodiment, the carrier 300 may be the material that a certain object is made of. For example, the beads 100 may be incorporated during glass batch preparation as a constituent of the glass batch. Because AION can withstand extreme temperatures, the beads 100 maintain their integrity during the intense glass-forming processes. Once a part of the material that an object is made of, the beads 100 may be used to monitor the health of the obj ect, as well as provide information to and from the object. Consider, for example, a wine glass for use in the restaurant industry, wherein the glass is embedded with a plurality of beads 100. The wine glass may be configured such that it has a certain known resonant frequency when the glass is filled above a certain ideal capacity. When a wine glass is deployed for use by a restaurant patron, the bar tender may ensure that the wine glass is filled at least to that capacity. Over the course of the patron's visit, external excitations may be initiated to excite the beads 100 in the wine glass. The resultant response (which may be measured by a sensor at or near the wine glass) can tell the bar tender whether the wine glass is below the ideal capacity, because the frequency and amplitude of the response as measured by the sensor will be different when the capacity is below the ideal level than when it is above the ideal level. If it is determined that the level of wine in the glass is below the ideal level, the bar tender can encourage the wait staff to try to sell additional wine to the patron.

[0035] Incorporating the beads 100 directly into the material may be further beneficial to provide increased strength to the material. And, as described elsewhere herein, the beads 100 may include a response unit 200 which may allow the beads 100 to respond to changes in the environment. For example, the beads 100 with a response unit 200 (e.g., a piezoelectric element) may be configured to sense impacts upon the wine glass which cause the wine glass to move from an inactive state (e.g., tip over). The location of the impact may be determined, as well as the force of the impact. When an impact is determined to be acting upon the wine glass causing movement of the glass, the piezoelectric elements in the beads 100 near the impact may begin to vibrate according to the force of the impact. This vibration may counteract the force of the impact, thus preventing the wine glass from undesirably tipping over.

[0036] In still yet another embodiment, AION may be provided as part of a layered substrate, such as a laminate. AION beads 100, such as those described above, may be distributed in a pattern between laminate sheets containing a flexible material, such as an adhesive carrier or other composition. The AION beads 100 may provide protection for sensors and/or the rigidity and bulletproof hardening to the more flexible substrates.

[0037] In another embodiment, an AION substrate with embedded sensors may be configured as a screen for a cell phone. The AION substrate may have superior scratch and breakage resistance as compared to other materials. The sensors may be configured for communication with other phone subsystems, and due to the transparent nature of the AION substrate, may be able to sense changes in the environment optically (e.g., that the phone is falling, in water, etc.) and take action (e.g., shut off sensitive systems) to prevent damage to the phone via the response unit 200. The sensors may also include the capability of biometric data acquisition such as sweat, blood, bacteria, urine and other biofluids/biofilms. By utilizing a smooth and chemically inert surface, the lab-on-a-chip functionality of an AION substrate could provide security, health, and legal screening capabilities (e.g., drug detection).

[0038] Because of the inert nature of aluminum oxynitride, the beads 100 may be specifically useful in biological applications. Here, the response unit 200 may include a fluorescent composition (e.g., fluid) which may fluoresce inside the body in response to an external stimulation. For example, one or more beads 100 may be swallowed by a user (e.g., via incorporation into a capsule with a dissolvable outer layer). Once inside the body, a medical professional can initiate external excitation (e.g., magnetic resonance via MRI) which may cause the material to fluoresce. The medical professional can run tests, and because of the transparent nature of the beads 100, can see the fluorescing material as the beads 100 travel through the user's body. This provides a unique perspective to medical professionals during the testing phase, which heretofore has not been possible. Uniquely, the beads 100 may be recoverable (e.g., through routine body movements) and recyclable.

[0039] Many different arrangements of the described invention are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention are described herein with the intent to be illustrative rather than restrictive.

Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the disclosed improvements without departing from the scope of the present invention. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures and description need to be carried out in the specific order described. The description should not be restricted to the specific described embodiments.