Precursors of engineered powders

• US 6,719,821 B2
• Filed: 02/08/2002
• Issued: 04/13/2004
• Est. Priority Date: 02/12/2001
• Status: Expired due to Term

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: NanoProducts Corporation (Nouryon BV)
• Inventors: Yadav, Tapesh, Mardilovich, Elena
• Primary Examiner(s): WYSZOMIERSKI, GEORGE P
• Application Number:
  US10/071,027
• Publication Number:
  US 20020178865A1
• Time in Patent Office: 795 Days
• Field of Search: 753/43, 753/51, 753/62, 753/69, 753/71, 753/70, 423/327.1, 423/331, 423/608, 423/622, 423/625, 423/628, 502/340, 502/341, 502/349, 502/355
• US Class Current: 75/343
• CPC Class Codes: B01J 19/0006 Controlling or regulating processes controlling or regulating in general G05
• CPC Class Codes: B01J 19/0013 Controlling the temperature of the process
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 2219/00063 of the reactants
• CPC Class Codes: B01J 2219/00094 Jackets
• CPC Class Codes: B01J 2219/00168 controlling the viscosity
• CPC Class Codes: B01J 2219/00177 controlling the pH
• CPC Class Codes: B01J 23/10 of rare earths
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 37/033 Using Hydrolysis
• CPC Class Codes: B01J 4/02 for feeding measured , i.e. prescribed quantities of reagents
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 13/36 by precipitation reactions in aqueous solutions C01B13/328 takes precedence
• CPC Class Codes: C01F 17/218 Yttrium oxides or hydroxides
• CPC Class Codes: C01F 17/235 Cerium oxides or hydroxides
• CPC Class Codes: C01F 7/34 Preparation of aluminium hydroxide by precipitation from solutions containing aluminium salts
• CPC Class Codes: C01P 2004/61 Micrometer sized, i.e. from 1-100 micrometer
• CPC Class Codes: C01P 2004/62 Submicrometer sized, i.e. from 0.1-1 micrometer
• CPC Class Codes: C01P 2004/64 Nanometer sized, i.e. from 1-100 nanometer
• CPC Class Codes: C01P 2006/13 thermal stability thereof at high temperatures
• CPC Class Codes: C09D 7/61 : inorganic

Abstract

The production and selection of precursor mixtures used to produce fine powders and methods for making fine powders using the selected precursor. The precursor mixture comprises at least one metal containing precursor, the metal containing precursor has an average molecular weight of less than 2000 grams per unit mol of the metal, the metal containing precursor has a normal boiling point greater than 350K, and the viscosity of the precursor mixture is between 0.1 to 250 cP. The precursor mixture is processed under conditions that produce a fine powder from the precursor mixture. Fine powders produced are of size less than 100 microns, preferably less than 10 micron, more preferably less than 1 micron, and most preferably less than 100 nanometers.

Claims

1. A method for making narrow size distribution nanoscale powders comprising:

selecting a precursor mixture wherein the mixture comprises at least one metal containing precursor;

the metal containing precursor has an average molecular weight of less than 2000 grams per unit mol of the metal;

the metal containing precursor has a normal boiling point greater than 350K;

a viscosity of the precursor mixture is between 0.1 to 250 cP;

processing the precursor mixture under conditions that produce nanoscale powder from the precursor mixture;

wherein the processing is conducted in a flow reactor system such that the axial velocity, axial length and axial dispersion coefficient in the flow reactor system yield a plug flow index of more than 50; and

quenching the nanoscale powder using Joule Thompson quench.

2. The method of claim 1 wherein the metal content in the precursor mixture is greater than 22% by weight.

3. The method of claim 1 wherein the act of processing the precursor mixture comprises reacting the precursor mixture with oxygen.

4. The method of claim 3 wherein heat released during the precursor mixture'"'"'s reaction with oxygen is on average greater than 1 kJ per liter of precursor mixture.

5. The method of claim 1 wherein the precursor mixture comprises at least two metal containing precursors.

6. The method of claim 1 wherein the precursor mixture comprises water.

7. The method of claim 1 wherein the precursor mixture comprises a hydrocarbon.

8. The method of claim 1, wherein the precursor mixture comprises an acetate.

9. The method of claim 1, wherein the precursor mixture comprises an alkanoate.

10. A product comprising of nanoscale powders prepared by the method of claim 1.

11. The method of claim 1 wherein the axial velocity, axial length and axial dispersion coefficient in the flow reactor system yield a plug flow index of more than 500.

12. The method of claim 1 wherein the precursor mixture comprises an organic chemical.

13. A method for making narrow size distribution nanoscale powders comprising:

selecting a precursor mixture wherein the mixture comprises at least one metal containing precursor;

the metal containing precursor has a normal boiling point greater than 350K;

a viscosity of the precursor mixture is between 0.1 to 250 cP;

processing the precursor mixture under conditions that produce nanoscale powder from the precursor mixture; and

wherein the processing is conducted in a flow reactor system such that the axial velocity, axial length and axial dispersion coefficient in the flow reactor system yield a plug flow index of more than 50.

14. The method of claim 13 wherein the precursor mixture comprises an organic chemical.

15. The method of claim 13 wherein the precursor mixture comprises water.