Aerosol method and apparatus, particulate products, and electronic devices made therefrom

• US 20050079349A1
• Filed: 09/02/2003
• Published: 04/14/2005
• Est. Priority Date: 02/24/1997
• Status: Active Grant

• Current Assignee: Cabot Corporation
• Original Assignee: Cabot Corporation
• Inventors: Hampden-Smith, Mark J., Caruso, James, Kodas, Toivo T., Powell, Quint H., Chandler, Clive D., Skamser, Daniel J.
• Granted Patent: US 7,128,852 B2
• Time in Patent Office: Days
• US Class Current: 428/402
• CPC Class Codes: B01J 13/02 Making microcapsules or microballoons for medical preparations A61K9/50
• CPC Class Codes: B01J 19/10 employing sonic or ultrasonic vibrations
• CPC Class Codes: B01J 19/2405 provoking a turbulent flow of the reactants, such as in cyclones, or having a high Reynolds-number
• CPC Class Codes: B01J 2/003 followed by coating of the granules to prevent the granules sticking together B01J2/30
• CPC Class Codes: B01J 2/006 Coating of the granules without description of the process or the device by which the granules are obtained to prevent the granules sticking together B01J2/30
• CPC Class Codes: B01J 2/02 by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
• CPC Class Codes: B01J 2/04 in a gaseous medium if combined with suspending the material in a gas, e.g. fluidised beds B01J2/16
• CPC Class Codes: B01J 2219/00112 involving reactant solids
• CPC Class Codes: B01J 2219/00155 using insulating materials or refractories
• CPC Class Codes: B01J 2219/00159 controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: B01J 2219/00162 controlling the pressure
• CPC Class Codes: B01J 2219/00166 controlling the residence time inside the reactor vessel
• CPC Class Codes: B01J 2219/00171 controlling the density
• CPC Class Codes: B01J 2219/00186 controlling the composition of the reactive mixture
• CPC Class Codes: B22F 1/052 characterised by a mixture of particles of different sizes or by the particle size distribution
• CPC Class Codes: B22F 1/054 Nanosized particles
• CPC Class Codes: B22F 1/065 Spherical particles
• CPC Class Codes: B22F 1/16 Metallic particles coated with a non-metal coated with lubricating or binding agents or with organic material B22F1/10
• CPC Class Codes: B22F 1/17 Metallic particles coated with metal
• CPC Class Codes: B22F 10/10 Formation of a green body
• CPC Class Codes: B22F 2202/01 : Use of vibrations
• CPC Class Codes: B22F 2202/11 : Use of irradiation
• CPC Class Codes: B22F 2998/00 : Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2999/00 : Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/02 : using physical processes
• CPC Class Codes: B22F 9/026 : Spray drying of solutions or suspensions
• CPC Class Codes: B22F 9/24 : starting from liquid metal compounds, e.g. solutions
• CPC Class Codes: B22F 9/30 : with decomposition of metal compounds, e.g. by pyrolysis
• CPC Class Codes: B24B 37/044 : characterised by the composition of the lapping agent
• CPC Class Codes: B82Y 30/00 : Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 13/18 : by thermal decomposition of compounds, e.g. of salts or hydroxides
• CPC Class Codes: C01B 13/185 : Preparing mixtures of oxides
• CPC Class Codes: C01B 17/20 : Methods for preparing sulfides or polysulfides, in general ammonium sulfides or polysulfides C01C; sulfides or polysulfides of metals, other than alkali metals, magnesium, calcium, strontium and barium, see the relevant groups of subclasses C01F or C01G, according to the metal
• CPC Class Codes: C01G 15/006 : Compounds containing, besides gallium, indium, or thallium, two or more other elements, with the exception of oxygen or hydrogen
• CPC Class Codes: C01G 23/003 : Titanates C01G23/001 takes precedence
• CPC Class Codes: C01G 23/006 : Alkaline earth titanates
• CPC Class Codes: C01G 25/00 : Compounds of zirconium
• CPC Class Codes: C01P 2002/60 : Compounds characterised by their crystallite size
• CPC Class Codes: C01P 2002/70 : defined by measured X-ray, neutron or electron diffraction data
• CPC Class Codes: C01P 2004/03 : obtained by SEM
• CPC Class Codes: C01P 2004/32 : Spheres
• CPC Class Codes: C01P 2004/34 : hollow
• CPC Class Codes: C01P 2004/50 : Agglomerated particles
• CPC Class Codes: C01P 2004/52 : highly monodisperse size distribution
• CPC Class Codes: C01P 2004/61 : Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2004/62 : Submicrometer sized, i.e. from 0.1-1 micrometer
• CPC Class Codes: C01P 2004/80 : Particles consisting of a mixture of two or more inorganic phases
• CPC Class Codes: C01P 2006/10 : Solid density
• CPC Class Codes: C01P 2006/22 : Rheological behaviour as dispersion, e.g. viscosity, sedimentation stability
• CPC Class Codes: C01P 2006/60 : Optical properties, e.g. expressed in CIELAB-values
• CPC Class Codes: C01P 2006/80 : Compositional purity
• CPC Class Codes: C09G 1/02 : containing abrasives or grinding agents abrasives as such C09K3/14; polishing of semi-conductors H01L
• CPC Class Codes: C09K 11/025 : non-luminescent particle coatings or suspension media
• CPC Class Codes: C09K 11/0805 : Chalcogenides
• CPC Class Codes: C09K 11/0877 : Borates
• CPC Class Codes: C09K 11/562 : Chalcogenides
• CPC Class Codes: C09K 11/565 : with zinc cadmium
• CPC Class Codes: C09K 11/567 : with alkaline earth metals
• CPC Class Codes: C09K 11/584 : with zinc or cadmium
• CPC Class Codes: C09K 11/595 : with zinc or cadmium
• CPC Class Codes: C09K 11/623 : with zinc or cadmium
• CPC Class Codes: C09K 11/625 : with alkaline earth metals
• CPC Class Codes: C09K 11/642 : with zinc or cadmium
• CPC Class Codes: C09K 11/643 : with alkaline earth metals
• CPC Class Codes: C09K 11/644 : Halogenides C09K11/641 takes precedence
• CPC Class Codes: C09K 11/662 : with zinc or cadmium
• CPC Class Codes: C09K 11/666 : Aluminates; Silicates
• CPC Class Codes: C09K 11/671 : Chalcogenides
• CPC Class Codes: C09K 11/672 : with zinc or cadmium
• CPC Class Codes: C09K 11/7701 : Chalogenides
• CPC Class Codes: C09K 11/7708 : Vanadates; Chromates; Molybdates; Tungstates
• CPC Class Codes: C09K 11/7718 : with alkaline earth metals
• CPC Class Codes: C09K 11/7729 : Chalcogenides
• CPC Class Codes: C09K 11/7731 : with alkaline earth metals
• CPC Class Codes: C09K 11/7746 : with alkaline earth metals
• CPC Class Codes: C09K 11/7769 : Oxides C09K11/7768 takes precedence
• CPC Class Codes: C09K 11/7771 : Oxysulfides
• CPC Class Codes: C09K 11/7776 : Vanadates; Chromates; Molybdates; Tungstates
• CPC Class Codes: C09K 11/7784 : Chalcogenides
• CPC Class Codes: C09K 11/7786 : with alkaline earth metals
• CPC Class Codes: C09K 11/7787 : Oxides C09K11/7785 takes precedence
• CPC Class Codes: C09K 11/7789 : Oxysulfides
• CPC Class Codes: C09K 11/7797 : Borates
• CPC Class Codes: C09K 3/1436 : Composite particles, e.g. coated particles
• CPC Class Codes: C09K 3/1463 : Aqueous liquid suspensions
• CPC Class Codes: C22C 1/1026 : starting from a solution or a suspension of (a) compound(s) of at least one of the alloy constituents
• CPC Class Codes: C22C 32/0089 : with other, not previously mentioned inorganic compounds as the main non-metallic constituent, e.g. sulfides, glass
• CPC Class Codes: H01G 4/0085 : Fried electrodes
• CPC Class Codes: H01J 29/20 : characterised by the luminescent material
• CPC Class Codes: H01L 21/3212 : by chemical mechanical polishing [CMP]
• CPC Class Codes: H01L 23/49883 : the conductive materials containing organic materials or pastes, e.g. for thick films for printed circuits H05K1/092
• CPC Class Codes: H01L 2924/00 : Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 : Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H01L 2924/09701 : Low temperature co-fired ceramic [LTCC]
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10T 428/12007 : Component of composite having metal continuous phase interengaged with nonmetal continuous phase
• CPC Class Codes: Y10T 428/12014 : having metal particles
• CPC Class Codes: Y10T 428/12056 : Entirely inorganic
• CPC Class Codes: Y10T 428/1216 : Continuous interengaged phases of plural metals, or oriented fiber containing
• CPC Class Codes: Y10T 428/12181 : Composite powder [e.g., coated, etc.]
• CPC Class Codes: Y10T 428/256 : Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/2982 : Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2991 : Coated

Abstract

Metal-carbon composite powders and methods for producing metal-carbon composite powders. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Claims

1-67. -67. (canceled)

68. A method for the production of metal-carbon composite particles, comprising the steps of:

a) generating an aerosol of droplets from a liquid wherein said liquid comprises a metal precursor and a carbon precursor;

b) moving said droplets in a carrier gas; and

c) heating said droplets to remove liquid therefrom and form metal-carbon composite particles.

69. A method as recited in claim 68, wherein said carrier gas comprises nitrogen.

70. A method as recited in claim 68, wherein said heating step comprises passing said droplets through a heating zone having a reaction temperature of from about 500°

C. to about 1000°

C.

72. A method as recited in claim 68, wherein said liquid is a solution comprising a platinum metal precursor selected from the group consisting of chloroplatinic acid, platinum nitrate, platinum sulfate and platinum oxalate.

73. A method as recited in claim 68, wherein said liquid is a solution comprising chloroplatinic acid.

74. A method as recited in claim 68, wherein said liquid is a solution comprising a silver metal precursor selected from the group consisting of silver nitrate and silver carboxylate.

75. A method as recited in claim 68, wherein said liquid is a solution comprising ruthenium nitrosyl nitrate.

76. A method as recited in claim 68, wherein said carbon precursor comprises a suspension of particulate carbon.

77. A method as recited in claim 68, wherein said carbon precursor comprises a suspension of semi-crystalline carbon.

78. A method as recited in claim 68, wherein said carbon precursor comprises a suspension of graphitic carbon.

79. A method as recited in claim 68, wherein said carbon precursor comprises a suspension of amorphous carbon.

80. A method as recited in claim 68, wherein said carbon precursor comprises a carbon-containing solution.

81. A method as recited in claim 68, wherein said step of generating an aerosol comprises ultrasonically atomizing said liquid.

82. A method as recited in claim 81, wherein said droplets in said aerosol have an average droplet size of not greater than about 10 μ

m.

83. A method as recited in claim 68, wherein said step of generating an aerosol comprises passing said liquid through a nozzle atomizer.

84. A method as recited in claim 83, wherein said droplets in said aerosol have an average droplet size of not greater than about 50 μ

m.

71. (canceled)