Zirconia particles
First Claim
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1. A method of making a composite material, said method comprising:
- forming a zirconia sol comprising;
preparing a first feedstock comprising a zirconium salt;
subjecting the first feedstock to a first hydrothermal treatment to form a zirconium-containing intermediate and a byproduct;
forming a second feedstock by removing at least a portion of the byproduct of the first hydrothermal treatment; and
subjecting the second feedstock to a second hydrothermal treatment to form a zirconia sol comprising zirconia particles;
adding an organic matrix material; and
removing at least a portion of a liquid phase from the zirconia sol.
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Abstract
Zirconia particles, methods of making zirconia particles, composite materials that contain the zirconia particles, methods of making the composite materials, and zirconia sols that contain the zirconia particles are described. The zirconia particles are substantially non-associated and have an average size no greater than 50 nanometers and may contain yttrium. The zirconia particles are prepared by a method that includes two separate hydrothermal treatments.
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Citations
20 Claims
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1. A method of making a composite material, said method comprising:
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forming a zirconia sol comprising; preparing a first feedstock comprising a zirconium salt; subjecting the first feedstock to a first hydrothermal treatment to form a zirconium-containing intermediate and a byproduct; forming a second feedstock by removing at least a portion of the byproduct of the first hydrothermal treatment; and subjecting the second feedstock to a second hydrothermal treatment to form a zirconia sol comprising zirconia particles; adding an organic matrix material; and removing at least a portion of a liquid phase from the zirconia sol. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of making a composite material, the method comprising:
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forming a zirconia sol using a hydrothermal method wherein the zirconia sol product of the hydrothermal method prior to any additional treatment comprises zirconia particles dispersed in an aqueous medium comprising a carboxylic acid, wherein the carboxylic acid has no greater than four carbon atoms and is substantially free of a polyether carboxylic acid and wherein the zirconia particles have an average primary particle size no greater than 30 nanometers, a dispersion index of 1 to 5, and a crystal structure that is at least 50 percent cubic, tetragonal, or a combination thereof; adding an organic matrix material to the zirconia sol; and removing at least a portion of the aqueous medium from the zirconia sol. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification