Shape engineering of nanoparticles

• US 7,857,244 B2
• Filed: 12/19/2006
• Issued: 12/28/2010
• Est. Priority Date: 01/03/2002
• Status: Expired due to Term

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Inventors: Pfaffenbach, Karl, Yadav, Tapesh
• Primary Examiner(s): Rosenbaum; Mark
• Application Number:
  US11/641,048
• Publication Number:
  US 20100230517A1
• Time in Patent Office: 1,470 Days
• Field of Search: 241/23, 241/30, 241/65, 977/840, 977/900
• US Class Current: 241/23
• CPC Class Codes: A62C 31/03 adjustable, e.g. from spray to jet or vice versa
• CPC Class Codes: B01J 12/005 carried out at high temperatures, e.g. by pyrolysis
• CPC Class Codes: B01J 12/02 for obtaining at least one reaction product which, at normal temperature, is in the solid state
• CPC Class Codes: B01J 19/24 Stationary reactors without moving elements inside B01J19/08, B01J19/26 take precedence; with stationary particles B01J8/02
• CPC Class Codes: B01J 2219/00094 Jackets
• CPC Class Codes: B01J 2219/00135 Electric resistance heaters
• CPC Class Codes: B01J 2219/00155 using insulating materials or refractories
• CPC Class Codes: B01J 2219/00177 controlling the pH
• CPC Class Codes: B01J 2219/0018 controlling the conductivity
• CPC Class Codes: B01J 2219/0894 Processes carried out in the presence of a plasma
• CPC Class Codes: B05B 1/12 capable of producing different kinds of discharge, e.g. either jet or spray having selectively-effective outlets B05B1/16
• CPC Class Codes: B22F 1/00 Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
• CPC Class Codes: B22F 1/054 Nanosized particles
• CPC Class Codes: B22F 1/056 Submicron particles having a size above 100 nm up to 300 nm
• CPC Class Codes: B22F 2202/13 Use of plasma
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/12 starting from gaseous material
• CPC Class Codes: B29C 70/58 comprising fillers only , e.g. particles, powder, beads, flakes, spheres B29C70/025 takes precedence, agglomerating hollow spheres to produce synthetic foam B29C70/66; compounding ingredients per se C08K
• CPC Class Codes: B32B 2309/022 Temperature vs pressure profiles
• CPC Class Codes: B82B 1/00 Nanostructures formed by manipulation of individual atoms or molecules, or limited collections of atoms or molecules as discrete units
• CPC Class Codes: B82Y 30/00 : Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 13/145 : After-treatment of oxides or hydroxides, e.g. pulverising, drying, decreasing the acidity
• CPC Class Codes: C01B 19/007 : Tellurides or selenides of metals C01B19/002 takes precedence
• CPC Class Codes: C01B 21/062 : with chromium, molybdenum or tungsten
• CPC Class Codes: C01B 32/956 : Silicon carbide
• CPC Class Codes: C01B 35/04 : Metal borides
• CPC Class Codes: C01F 11/06 : of carbonates
• CPC Class Codes: C01F 17/206 : oxide or hydroxide being the only anion
• CPC Class Codes: C01F 5/06 : by thermal decomposition of magnesium compounds calcining magnesite or dolomite C04B2/10
• CPC Class Codes: C01G 23/006 : Alkaline earth titanates
• CPC Class Codes: C01G 41/02 : Oxides; Hydroxides
• CPC Class Codes: C01G 53/006 : Compounds containing, besides nickel, two or more other elements, with the exception of oxygen or hydrogen nickelates C01G53/40
• CPC Class Codes: C01P 2002/72 : by d-values or two theta-values, e.g. as X-ray diagram
• CPC Class Codes: C01P 2004/03 : obtained by SEM
• CPC Class Codes: C01P 2004/04 : obtained by TEM, STEM, STM or AFM
• CPC Class Codes: C01P 2004/51 : Particles with a specific particle size distribution
• 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 2004/64 : Nanometer sized, i.e. from 1-100 nanometer
• CPC Class Codes: C01P 2006/12 : Surface area
• CPC Class Codes: C01P 2006/40 : Electric properties
• CPC Class Codes: C01P 2006/80 : Compositional purity
• CPC Class Codes: C04B 2/10 : Preheating, burning calcining or cooling decarbonation during burning of cement raw materials C04B7/43; obtaining CaO or MgO otherwise than by thermal decomposition of the corresponding carbonates C01F11/02, C01F5/02
• CPC Class Codes: C04B 20/0004 : Microcomposites or nanocomposites, e.g. composite particles obtained by polymerising monomers onto inorganic materials
• CPC Class Codes: C04B 2235/6025 : Tape casting, e.g. with a doctor blade
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/62222 : obtaining ceramic coatings coating of mortars, concrete, artificial or natural stone or ceramics C04B41/45; laminated ceramic products B32B18/00; coating metallic materials C23; coating of glass C03C17/00, applying ceramic coatings on silicon for semi-conductor purposes H01L
• CPC Class Codes: C04B 35/638 : Removal thereof
• CPC Class Codes: C04B 41/52 : Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
• CPC Class Codes: C04B 41/89 : for obtaining at least two superposed coatings having different compositions
• CPC Class Codes: C08K 2201/011 : Nanostructured additives
• CPC Class Codes: C08K 2201/016 : Additives defined by their aspect ratio
• CPC Class Codes: C08K 3/01 : characterized by their specific function
• CPC Class Codes: C08K 3/08 : Metals
• CPC Class Codes: C09C 3/006 : Combinations of treatments provided for in groups C09C3/04 - C09C3/12
• CPC Class Codes: C09C 3/04 : Physical treatment, e.g. grinding, treatment with ultrasonic vibrations C09C3/006 takes precedence
• CPC Class Codes: H01C 17/06513 : characterised by the resistive component
• CPC Class Codes: H01C 7/112 : ZnO type
• CPC Class Codes: H01G 4/12 : Ceramic dielectrics H01G4/085 takes precedence
• CPC Class Codes: H01G 4/33 : Thin- or thick-film capacitors thin- or thick-film circuits H01L27/00; capacitors without a potential-jump or surface barrier specially adapted for integrated circuits, details thereof, multistep manufacturing processes therefor H01L28/40
• CPC Class Codes: H01M 4/9066 : of metal-ceramic composites or mixtures, e.g. cermets
• CPC Class Codes: H01M 8/1213 : characterised by the electrode/electrolyte combination or the supporting material
• CPC Class Codes: H01M 8/1246 : the electrolyte consisting of oxides
• CPC Class Codes: H01M 8/1253 : the electrolyte containing zirconium oxide
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10S 977/84 : Manufacture, treatment, or detection of nanostructure
• CPC Class Codes: Y10S 977/90 : having step or means utilizing mechanical or thermal property, e.g. pressure, heat

Abstract

Methods for preparing high aspect ratio nanomaterials from spherical nanomaterials useful for oxides, nitrides, carbides, borides, metals, alloys, chalcogenides, and other compositions.

Claims

1. A method for modifying the shape of nanomaterials comprising:

processing nanomaterials of a first aspect ratio by shear at a temperature greater than the softening temperature of the nanomaterials, wherein the temperature is between 0.2*T_m and 0.95*T_m, wherein T_m is the melting point temperature of the nanomaterials in Kelvin; and

collecting nanomaterials with an aspect ratio different than the first aspect ratio.

2. The method of claim 1 wherein the nanomaterials comprise an inorganic substance selected from the group consisting of:

oxides, carbides, nitrides, chalcogenides, metals, and alloys.

3. The method of claim 1 wherein the nanomaterials comprise a purity greater than 99.9% by metal basis.

4. The method of claim 1, further comprising providing nanomaterials of a first aspect ratio, the providing comprising:

vaporizing at least one precursor in a thermal reactor; and

processing the at least one vaporized precursor under thermokinetic conditions that favor nucleation of solid nanopowder from the vaporized precursor.

5. The method of claim 4, further comprising:

atomizing the at least one precursor before vaporizing the at least one precursor; and

quenching the solid nanopowder nucleated from the vaporized precursor.

6. The method of claim 1, wherein the nanomaterials comprise inorganic nanoparticles having a mean particle size less than 250 nanometers.

7. A method for modifying the shape of nanomaterials comprising:

processing nanomaterials of a first aspect ratio by shear at a temperature greater than the softening temperature of the nanomaterials but less than a melting temperature of the nanomaterials; and

collecting nanomaterials with an aspect ratio different than the first aspect ratio.

8. The method of claim 7, further comprising providing nanomaterials of a first aspect ratio, the providing comprising:

vaporizing at least one precursor in a thermal reactor; and

processing the at least one vaporized precursor under thermokinetic conditions that favor nucleation of solid nanopowder from the vaporized precursor.

9. The method of claim 8, further comprising:

atomizing the at least one precursor before vaporizing the at least one precursor; and

quenching the solid nanopowder nucleated from the vaporized precursor.

10. The method of claim 7, wherein the nanomaterials comprise inorganic nanoparticles having a mean particle size less than 250 nanometers.

11. A method for modifying the shape of nanomaterials comprising:

processing inorganic nanoparticles of a first aspect ratio and having a mean particle size less than 250 nanometers by shear at a temperature greater than the softening temperature of the nanoparticles but less than a melting temperature of the nanoparticles;

wherein the processing changes the aspect ratio of the nanoparticles.

12. The method of claim 11, wherein the nanoparticles have a mean particle size less than 100 nanometers.

13. The method of claim 11, wherein the temperature is between 0.2*T_m and 0.95*T_m wherein T_m is the melting point of the nanoparticles in Kelvin.

14. The method of claim 11, wherein the nanoparticles comprise a substance selected from the group consisting of:

oxides, carbides, nitrides, chalcogenides, metals, and alloys.

15. The method of claim 11, wherein the nanoparticles comprise a purity greater than 99.9% by metal basis.

16. The method of claim 11, further comprising providing nanoparticles of a first aspect ratio, the providing comprising:

atomizing at least one precursor;

vaporizing the at least one precursor in a thermal reactor;

processing the at least one vaporized precursor under thermokinetic conditions that favor nucleation of solid nanoparticles from the vaporized precursor; and

quenching the solid nanoparticles nucleated from the vaporized precursor.