Shaped microcomponent via reactive conversion of biologically-derived microtemplates

• US 7,067,104 B2
• Filed: 05/30/2002
• Issued: 06/27/2006
• Est. Priority Date: 05/30/2001
• Status: Expired due to Fees

• Current Assignee: Ohio State University
• Original Assignee: Ohio State University
• Inventors: Sandhage, Kenneth H.
• Primary Examiner(s): Lankford, Jr., Leon B.
• Assistant Examiner(s): Ford, Allison M.
• Application Number:
  US10/158,582
• Publication Number:
  US 20030099763A1
• Time in Patent Office: 1,489 Days
• Field of Search: 977/1, 423/325, 423/335, 423/339, 423/155, 423/179, 423/111, 423/69
• US Class Current: 423/592.1
• CPC Class Codes: B81B 2201/034 Electrical rotating micromachines
• CPC Class Codes: B81B 2201/035 Microgears
• CPC Class Codes: B81C 1/00 Manufacture or treatment of devices or systems in or on a substrate B81C3/00 takes precedence
• CPC Class Codes: B81C 99/0085 using moulds and master templates, e.g. for hot-embossing
• CPC Class Codes: G01N 33/54346 Nanoparticles
• CPC Class Codes: G01N 33/54353 with ligand attached to the carrier via a chemical coupling agent coatings G01N33/54393
• CPC Class Codes: G01N 33/544 the carrier being organic
• CPC Class Codes: Y10S 977/811 Of specified metal oxide composition, e.g. conducting or semiconducting compositions such as ITO, ZnOx
• CPC Class Codes: Y10S 977/84 Manufacture, treatment, or detection of nanostructure
• CPC Class Codes: Y10S 977/89 Deposition of materials, e.g. coating, cvd, or ald
• CPC Class Codes: Y10S 977/90 having step or means utilizing mechanical or thermal property, e.g. pressure, heat

Abstract

The present invention is focused on a revolutionary, low-cost (highly-scaleable) approach for the mass production of three-dimensional microcomponents: the biological reproduction of naturally-derived, biocatalytically-derived, and/or genetically-tailored three-dimensional microtemplates (e.g., frustules of diatoms, microskeletons of radiolarians, shells of mollusks) with desired dimensional features, followed by reactive conversion of such microtemplates into microcomponents with desired compositions that differ from the starting microtemplate and with dimensional features that are similar to those of the starting microtemplate. Because the shapes of such microcomponents may be tailored through genetic engineering of the shapes of the microtemplates, such microcomposites are considered to be Genetically-Engineered Materials (GEMs).

Claims

1. A method for the production of a shaped microcomponent, comprising:

a) providing at least one biologically-derived silica microtemplate having an original chemical composition and an original dimensional feature, wherein the at least one biologically-derived silica microtemplate is a frustule of a diatom species; and

b) subjecting said at least one biologically-derived silica microtemplate to at least one chemical reaction so as to at least partially convert said at least one biologically-derived silica microtemplate into a shaped microcomponent comprising a solid oxide, wherein the at least one chemical reaction is selected from the group consisting of additive reaction, metathetic reaction, oxidation-reduction reaction, or combinations thereof; and

wherein at least a portion of the shaped microcomponent has a different chemical composition than the biologically-derived silica microtemplate, but substantially the same dimensional feature as the biologically-derived silica microtemplate.

2. The method of claim 1, wherein said at least one biologically-derived microtemplate is a naturally-occurring microtemplate.

3. The method of claim 1, wherein said at least one biologically-derived microtemplate is a biologically-derived mineral containing article having a shape provided by nature.

4. The method of claim 1, wherein said at least one biologically-derived microtemplate is derived from a genetically altered organism that constructs said microtemplate having a dimensional feature different than a microtemplate produced by a non-altered organism of the same type as said genetically altered organism.

5. The method of claim 1, wherein said chemical reaction is an additive reaction of the following type:

aA_bY_c+M_dX_e→

aA_bY_c·

M_dX_e

where A_bY_c is a reactant, M_dX_e is a constituent of the said at least one biologically-derived microtemplate, and aA_bY_cM_dX_e is an ionically or covalently bonded solid reaction product that is a solid compound, a solid solution, or a solid mixture that is retained in the said shaped microcomponent; and

wherein a, b, c, d, and e are stoichiometric coefficients.

6. The method of claim 5 wherein aA_bY_c.M_dX_e is selected from the group consisting of solid oxides, solid oxide compounds, oxide solid solutions, solid oxide mixtures, and mixtures thereof.

7. The method of claim 5 wherein aA_bY_c.M_dX_e is selected from the group consisting of silicon oxide-bearing compounds, silicon oxide-bearing solid solutions, silicon oxide-bearing mixtures, and mixtures thereof.

8. The method of claim 7 wherein said silicon oxide-bearing compound is selected from the group consisting of aluminosilicates, alkali silicates, alkaline earth silicates, alkali aluminosilicates, alkaline earth aluminosilicates, borosilicates, cadmium silicates, cobalt silicates, erbium silicates, iron silicates, lead silicates, manganese silicates, neodymium silicates, nickel silicates, yttrium silicates, ytterbium silicates, zinc silicates, zircon, and mixtures thereof.

9. The method of claim 5 wherein aA_bY_c.M_dX_e is selected from the group consisting of calcium oxide-bearing compounds, calcium oxide-bearing solid solutions, calcium oxide-bearing mixtures, and mixtures thereof.

10. The method of claim 9 wherein said calcium oxide-bearing compound is selected from the group consisting of calcium alkali-silicates, calcium aluminates, calcium aluminosilicates, calcium alkali-aluminosilicates, calcium bismuthates, calcium borates, calcium cerates, calcium chromites, calcium cuprates, calcium ferrites, calcium gadolinium oxides, calcium gallates, calcium germanates, calcium hafnate, calcium manganates, calcium molybdates, calcium niobates, calcium phosphates, calcium hydroxyapatite, calcium plumbates, calcium silicates, calcium stannates, calcium sulfates, calcium tantalates, calcium titanates, calcium tungstates, calcium uranium oxides, calcium vanadates, calcium yttrium oxides, calcium zirconates, and mixtures thereof.

11. The method of claim 1, wherein said chemical reaction is a metathetic reaction of the following type:

aA_bY_c+M_dX_e→

aA_bX_e/a+M_dY_ca

where A_bY_c is a reactant, M_dX_e is a constituent of the said at least one biologically-derived microtemplate, aA_bX_e/a is an onically or covalently bonded first solid reaction product that is a solid compound, a solid solution, or a solid mixture that is retained in the said shaped microcomponent, and M_dY_ca is a second reaction product; and

wherein a, b, c, d, e, e/a, and ca are stoichiometric coefficients.

12. The method of claim 11 wherein aA_bX_e/a is selected from the group consisting of solid oxides, solid oxide compounds, oxide solid solutions, solid oxide mixtures, and mixtures thereof.

13. The method of claim 11 wherein aA_bX_e/a is selected from the group consisting of Ethium oxide, beryllium oxide, boron oxide, sodium oxide, magnesium oxide, aluminum oxide, potassium oxide, calcium oxide, titanium oxide, vanadium oxide, chromium oxide, manganese oxide, iron oxide, cobaft oxide, nickel oxide, copper oxide, zinc oxide, germanium oxide, rubidium oxide, strontium oxide, yttrium oxide, zirconium oxide, niobium oxide, molybdenum oxide, cadmium oxide, indium oxide, tin oxide, antimony oxide, cesium oxide, barium oxide, lanthanum oxide, hafnium oxide, tantalum oxide, tungsten oxide, lead oxide, bismuth oxide, cerium oxide, neodymium oxide, samarium oxide, europium oxide, gadolinium oxide, dysprosium oxide, holmium oxide, erbium oxide, ytterbium oxide, and mixtures thereof.

14. The method of claim 1, wherein said chemical reaction is an oxidation-reduction reaction of the foliowing type:

yA+aM_xO_z→

yAO_za/y+axM

where A is a reactant M_xO_z is an oxide constituent of the said at least one bioiogicaily-derived microteniplate, yAO_za/y is an oxide first solid reaction product that le a solid compound, a solid solution, or a solid mixture that le retained in the said shaped microcomponent, and M is a second reaction product and wherein y, a, x, z, za/y, and ax are stoichiometric coefficlenta.

15. The method of claim 14 wherein yAO_za/y is selected from the group consisting of solid oxides, solid oxide compounds, oxide solid solutions, solid oxide mixtures, and mixtures thereof.

16. The method of claim 14 wherein yAO_za/y is selected from the group consisting of lithium oxide, beryllium oxide, magnesium oxide, aluminum oxide, calcium oxide, titanium oxide, strontium oxide, yttrium oxide,-zirconium oxide, antimony oxide, barium oxide, lanthanum oxide,hafnium oxide, cerium oxide, neodymium oxide, praseodymium oxide, samarium oxide, europium oxide, gadolinium oxide, dysprosium oxide,-holmium oxide, erbium oxide, thulium oxide, lutetium oxide, ytterbium oxide, and mixtures thereof.

17. The method of claim 1, wherein said chemical reaction involves at least two reactions selected from the group consisting of an additive reaction of the following type:

aA_bY_c+M_dX_e→

aA_bY_c·

M_dX_e

where A_bY_c is a reactant, M_dX_e is a constituent of the said at least one biologically-derived microtemplate, and aA_bY_c·

M_dX_e is an ionically or covalently bonded solid reaction product that is a solid compound, a solid solution, or a solid mixture that is retained in the said shaped microcomponent; and

wherein a, b, c, d, and e are stoichiometric coefficients;

a metathetic reaction of the following type;

aA_bY_c+M_dX_e→

aA_bX_e/a+M_dY_ca

where A_bY_c is a reactant, M_dX_e is a constituent of the said at least one biologically-derived microtemplate, aA_bX_e/a is an ionically or covalently bonded first solid reaction product that is a solid compound, a solid solution, or a solid mixture that is retained in the said shaped microcomponent, and MdYca is a second reaction product; and

wherein a, b, c, d, e, e/a, and ca are stoichiometric coefficients; and

an oxidation-reduction reaction of the following type;

yA+aM_xO_z→

yAO_za/y+axM

where A is a reactant, M_xO_z is an oxide constituent of the said at least one biologically-derived microtemplate, yAO_za/y is an oxide first solid reaction product that is a solid compound, a solid solution, or a solid mixture that is retained in the said shaped microcomponent, and M is a second reaction product; and

wherein y, a, x, z, zaly, and ax are stoichiometric coefficients; and

combinations thereof.

18. The method of claim 1, wherein said shaped microcomponent defines a cavity wherein said cavity is provided with at least one substance not native to said biologically-derived microtemnlate.

19. The method of claim 18, wherein said at least one substance is a pharmaceutically active substance.

20. The method of claim 1 wherein said shaped microcomponent possesses a shape selected from the group consisting of a solid microcylinder, a microtube, a solid microbar, a hollow microbar, a solid microsphere, a hollow microsphere, a solid microdisk, a hollow microdisk, a microwheel, a microgear, a microrotor, a microplate, a microtetrahedron, a microwedge, a microtetrakaidecahedron, a microspring, a microspiral, a microlever, a microcantilever, a solid microcone, a microfunnel, a microhoneycomb, a micromesh, a solid microcube, a hollow microcube, a solid microfiber, a hollow microfiber, and combinations thereof.

21. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 1 millimeter in size.

22. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 100 microns in size.

23. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 25 microns in size.

24. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 10 microns in size.

25. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 1 micron in size.

26. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 100 nanometers in size.

27. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 25 nanometers in size.

28. The method of claim 1 wherein said shaped microcomponent possesses at least one dimensional feature that is less than 10 nanometers in size.