Methods for producing composite nanoparticles

• US 6,855,426 B2
• Filed: 05/10/2002
• Issued: 02/15/2005
• Est. Priority Date: 08/08/2001
• Status: Expired due to Term

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: NanoProducts Corporation (Nouryon BV)
• Inventors: Yadav, Tapesh
• Primary Examiner(s): Chen, Vivian
• Application Number:
  US10/143,995
• Publication Number:
  US 20030035955A1
• Time in Patent Office: 1,012 Days
• Field of Search: 428/323, 428/325, 428/328, 428/329, 428/330, 428/331, 428/357, 428/402, 428/403, 428/404, 427/180, 427/201, 427/204, 427/205, 427/212, 427/215, 427/216
• US Class Current: 428/403
• CPC Class Codes: B29B 2009/125 Micropellets, microgranules, microparticles
• CPC Class Codes: B29B 9/08 by agglomerating smaller particles
• CPC Class Codes: B29B 9/12 characterised by structure or composition
• CPC Class Codes: B82Y 25/00 Nanomagnetism, e.g. magnetoimpedance, anisotropic magnetoresistance, giant magnetoresistance or tunneling magnetoresistance
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01P 2002/02 Amorphous compounds
• CPC Class Codes: C01P 2002/60 Compounds characterised by their crystallite size
• CPC Class Codes: C01P 2004/54 Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension
• CPC Class Codes: C01P 2004/62 Submicrometer sized, i.e. from 0.1-1 micrometer
• CPC Class Codes: C01P 2006/12 Surface area
• CPC Class Codes: C08K 2201/011 Nanostructured additives
• CPC Class Codes: C08K 2201/013 Additives applied to the surface of polymers or polymer particles
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/252 Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/256 Heavy metal or aluminum or compound thereof
• CPC Class Codes: Y10T 428/257 Iron oxide or aluminum oxide
• CPC Class Codes: Y10T 428/258 Alkali metal or alkaline earth metal or compound thereof
• CPC Class Codes: Y10T 428/259 Silicic material
• CPC Class Codes: Y10T 428/29 Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2991 : Coated
• CPC Class Codes: Y10T 428/2993 : Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2998 : including synthetic resin or polymer

Abstract

Size-confined nanocomposite powders and methods for their manufacture are provided by coating fine powders with a nanoscale powder of a different composition. The nanocomposite plastics disclosed offer performance characteristics approaching those of metals and alloys. The nanocomposite powders are alternatively used for dispersion strengthening of metals, alloys, and ceramics. Novel materials based nanotechnology for energy devices and programmable drug delivery are disclosed.

Claims

1. A method of forming interface engineered material comprising:

selecting a fine powder of a material of first composition;

selecting nanoparticles of a second composition different an the first composition;

chemically bonding the nanoparticles to the surface of the fine a powders thereby creating a nanocomposite powder with an interfacial layer on the fine powder surface. said interfacial layer of third composition distinct from the first composition and the second composition, and wherein the composition of said interfacial layer results from the chemical bonding of said nanoparticles of the second composition and the fine powders of the first composition.

2. The method of claim 1 further comprising a step wherein the nanocomposite powders are processed into a finished part.

3. The method of claim 1 wherein the nanoparticle loading is less than 5% by weight.

4. The method of claim 1 wherein the first composition is selected from the group consisting of:

metal, alloy, an ceramic.

5. The method of claim 1 wherein the second composition is selected from the group consisting of:

carbide, nitride, boride, chalcogenide, halide, metal, and alloy.

6. The method of claim 1 wherein the fine powder of first composition is a submicron powder.

7. The method of claim 1 wherein the fine powder of first composition is a nanoscale powder.

8. The method of claim 1 wherein the second composition is an oxide.

9. A nanocomposite powder comprising fine powders of first composition and nanoparticles of second composition, wherein the nanoparticles are chemically bonded to the fine powders there creating a nanocomposite powder with an interfacial layer on the fine powder surface, said interfacial layer of composition distinct from the first composition and the second composition, and wherein the composition of said interfacial layer results from the chemical bonding of said nanoparticles of the second composition and the fine powders of the first composition;

and

wherein the size-confined nanocomposite powder has an average domain size of less than 5 micron.

10. A product prepared from the nanocomposite powder of claim 9.

11. The nanocomposite powder claim 9 wherein the nanocomposite powder comprises at least one metal.

12. The nanocomposite powder of claim 9 wherein the nanocomposite powder comprises at least one polymer.

13. The nanocomposite powder of claim 9 wherein the nanocomposite powder comprises at least one ceramic.

14. The nanocomposite powder of claim 9 wherein the nanocomposite powder comprises at least one glass.

15. The nanocomposite powder of claim 9 wherein the nanocomposite powder comprises at least one biologically active substance.

16. The nanocomposite powder of claim 9 wherein the fine powders are magnetic and the nanoparticles are electrically insulating.

17. The nanocomposite powder of claim 9 wherein the nanoparticles comprise an electrically conducting substance.

18. The nanocomposite powder of claim 9 wherein the fine powders are submicron powders.

19. The nanocomposite powder claim 9 wherein the fine powders are nanoparticles.

20. The nanocomposite powder of claim 9 wherein the nanocomposite powder comprises powder with aspect ratio greater than one and less than 1,000,000.