Nano-dispersed powders and methods for their manufacture
First Claim
1. A method for producing a dispersed powder comprising nano-sized particles dispersed on and attached to the surface of carrier particles, the method comprising:
- providing a slurry precursor comprising a mixture of a metal-containing precursor and carrier particles;
heating the slurry precursor to a temperature greater than 3000°
C., wherein the slurry precursor is converted to the vapor phase; and
cooling the vapor phase to produce the dispersed powder.
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Abstract
Dispersed powders are disclosed that comprise fine nanoscale powders dispersed on coarser carrier powders. The composition of the dispersed fine powders may be oxides, carbides, nitrides, borides, chalcogenides, metals, and alloys. Fine powders discussed are of sizes less than 100 microns, preferably less than 10 micron, more preferably less than 1 micron, and most preferably less than 100 nanometers. Methods for producing such powders in high volume, low-cost, and reproducible quality are also outlined. Such powders are useful in various applications such as catalysts, sensor, electronic, electrical, photonic, thermal, biomedical, piezo, magnetic, catalytic and electrochemical products.
251 Citations
30 Claims
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1. A method for producing a dispersed powder comprising nano-sized particles dispersed on and attached to the surface of carrier particles, the method comprising:
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providing a slurry precursor comprising a mixture of a metal-containing precursor and carrier particles;
heating the slurry precursor to a temperature greater than 3000°
C., wherein the slurry precursor is converted to the vapor phase; and
cooling the vapor phase to produce the dispersed powder. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method for producing a dispersed powder comprising nano-sized particles dispersed on and attached to the surface of carrier particles, the method comprising:
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combining nano-scale powders and carrier particles to form a slurry precursor;
heating the slurry precursor to a temperature greater than 3000°
C., wherein the slurry precursor is converted to the vapor phase; and
cooling the vapor phase to produce the dispersed powder.
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12. A method for producing a dispersed powder comprising nano-sized particles dispersed on and attached to the surface of carrier particles, the method comprising:
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providing a slurry precursor comprising a mixture of a metal-containing precursor and carrier particles; and
mechanically milling said mixture to produce said dispersed powder.
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13. A dispersed powder comprising:
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a sub-micron carrier particle having a first composition; and
nano-scale particles of a second composition that are dispersed on and attached to the surface of the carrier particle in a mechanically stable state, wherein the attached particles are smaller than the carrier particle and wherein at least two neighboring attached particles on the surface of said carrier particle do not touch each other at 300 Kelvin. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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Specification