Versatile oxygen sorbents and devices
First Claim
1. A regenerable sorbent for removing trace amounts of oxygen from either a gas-stream or a closed system, the sorbent comprises:
- a mixed-oxide material composed by weight of about 1% to about 99% Ce2O3, about 0% to about 99% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount of 0% to about 10%, on a surface of said mixed oxide material.
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Abstract
The invention according to one aspect provides oxygen sorbent materials, which are able to remove trace amounts of oxygen in either a gas-flow or an enclosed system over a wide temperature range. In particular, the invention relates to bulk solid oxygen sorbents that can lower equilibrium oxygen concentrations to below 1 part per trillion (1 ppt). The oxygen sorbents have high surface area, nano-sized crystalline mixed oxides that include cerium oxide, zirconium oxide and preferably yttrium oxide, and an aliquot of catalytic materials such as precious metal. The present sorbents can work in noxious environments, since the materials are not sensitive to toxic elements, which would typically poison conventional catalysts. In another aspect, a product and method for fabricating an opto-electronic device that includes a getter material, incorporating an iteration of the sorbent material, is provided. The getter material operates by bulk transport and has a capacity to absorb and retain large quantities of oxygen per volume and other contaminants over a wide temperature range. This is a useful feature for opto-electronic—also known as photonic—devices, especially those with polymeric components, since they often suffer from photo-degradation caused by the presence of gaseous oxygen and other contaminants in the optical pathway.
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Citations
77 Claims
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1. A regenerable sorbent for removing trace amounts of oxygen from either a gas-stream or a closed system, the sorbent comprises:
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a mixed-oxide material composed by weight of about 1% to about 99% Ce2O3, about 0% to about 99% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount of 0% to about 10%, on a surface of said mixed oxide material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A method of preparing an oxygen sorbent, the method comprising:
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a) preparing a mixture of mixed-oxide compounds;
b) precipitating a mixed metal hydroxide with a concentrated base solution of mixed bases, from said mixed-oxide mixture;
c) collecting said hydroxide precipitate and washing with a liquid-phase solvent;
d) calcinating said hydroxide precipitate to a mixed-oxide material in flowing air. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 37, 38, 39, 40, 41, 42, 43)
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44. A process for producing a single-phase mixed oxide material in a ceria-zirconia system, the process comprising:
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a) preparing a mixture of cerium and zirconium compounds in solution;
b) precipitating a mixed metal hydroxide with a concentrated base solution of mixed bases, from said mixed-oxide mixture by adding said mixed-oxide mixture into said base solution;
c) collecting said hydroxide precipitate and washing with a liquid-phase solvent;
d) calcinating said hydroxide precipitate to a mixed oxide material in flowing air.
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45. A regenerable sorbent for removing trace amounts of oxygen from either a gas-stream or a closed system, the sorbent is made according to a method comprising:
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a) preparing a mixture of mixed-oxide compounds;
b) precipitating a mixed metal hydroxide with a concentrated base solution of mixed bases, from said mixed-oxide mixture by adding said mixed-oxide mixture into said base solution;
c) collecting said hydroxide precipitate and washing with a liquid-phase solvent;
d) calcinating said hydroxide precipitate to a mixed oxide material in flowing air.
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46. A device comprising an enclosure, a component susceptible to degradation from oxygen, and a getter material comprising a mixed-oxide carrier composed by weight of about 20% to about 95% Ce2O3, about 5% to about 90% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers;
- and at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof, on a surface of said mixed oxide carrier, and an inorganic binder and components chosen from the group including MCM-22, -24, -30, -41, zeolite type A, X, Y, L, ZSM-5, mordenite, cloverite, porous silica, porous borosilicate, activated carbon, activated alumina, porous alumina, and mixtures thereof. - View Dependent Claims (47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57)
- and at least one of the following transition metals;
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58. A hermetically sealed opto-electronic package comprising:
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a sealed enclosure in which there is an atmosphere and a component that is adversely affected by the presence of gaseous oxygen or other impurities in said atmosphere; and
a getter material comprising a mixed-oxide material composed by weight of about 20% to about 95% Ce2O3, about 5% to about 80% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount, on a surface of said mixed oxide material, and an inorganic binder and components chosen from the group including MCM-22, -24, -30, -41, zeolite type A, X, Y, L, ZSM-5, mordenite, cloverite, porous silica, porous borosilicate, activated carbon, activated alumina, porous alumina, and mixtures thereof. - View Dependent Claims (59)
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60. A method of providing a virtually O2-free atmosphere in an opto-electronic device package, the method comprises:
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a) providing a photonic device;
b) providing a housing;
c) providing a getter material comprising a mixed-oxide material composed by weight of about 20% to about 95% Ce2O3, about 5% to about 80% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount, on a surface of said mixed oxide material;
d) enclosing said photonic device and said getter within said housing; and
e) removing oxygen and other contaminant vapors from said opto-electronic component. - View Dependent Claims (61, 62, 63)
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64. An opto-electronic system comprising:
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a photonic device;
a housing; and
a getter material comprising a mixed-oxide material composed by weight of about 20% to about 95% Ce2O3, about 5% to about 80% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount, on a surface of said mixed oxide material. - View Dependent Claims (65)
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66. A photonic component getter comprising:
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a regenerable sorbent, the sorbent comprises;
a mixed-oxide material composed by weight of about 20% to about 95% Ce2O3, about 5% to about 80% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount, on a surface of said mixed oxide material;
assemblying said getter material in a package assembly. - View Dependent Claims (67)
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68. A method of making a photonic component getter material, the method comprising:
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a) preparing a mixture of mixed-oxide compounds;
b) precipitating a mixed metal hydroxide with a concentrated base solution of mixed bases, from said mixed-oxide mixture;
c) collecting said hydroxide precipitate and washing with a liquid-phase solvent;
d) impregnating metal oxides on and in said mixed oxide powder;
e) calcinating said hydroxide precipitate to said mixed oxide in flowing air; and
f) activating said hydroxide precipitate;
g) shaping said hydroxide precipitate into a form;
h) assembling said getter material in a package assembly. - View Dependent Claims (69, 70, 71, 72)
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73. A method of packaging an opto-electronic device, the method comprising:
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providing a regenerable sorbent, the sorbent comprises;
a mixed-oxide material composed by weight of about 20% to about 95% Ce2O3, about 5% to about 80% ZrO2, and 0% to about 25% RxOy, wherein RxOy is another metal oxide, and x and y are integers; and
at least one of the following transition metals;
Fe, Co, Ni, Cu, Ru, Pd, Rh, Pt, Ir, Os, or their oxides or mixtures thereof in catalytic amount, on a surface of said mixed oxide material;
assemblying said sorbent in a package assembly. - View Dependent Claims (74, 75, 76, 77)
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Specification