Non-spherical nanopowder derived nanocomposites

• US 6,916,872 B2
• Filed: 05/30/2003
• Issued: 07/12/2005
• Est. Priority Date: 09/03/1996
• Status: Expired due to Term

• Current Assignee: PPG Industries Ohio Incorporated (Nouryon BV)
• Original Assignee: NanoProducts Corporation (Nouryon BV)
• Inventors: Yadav, Tapesh, Kostelecky, Clayton
• Primary Examiner(s): Wyrozebski, Katarzyna
• Application Number:
  US10/449,282
• Publication Number:
  US 20030207978A1
• Time in Patent Office: 774 Days
• Field of Search: 524/430, 524/431, 524/432, 524/433, 524/434, 524/435, 524/436, 524/404, 524/413, 524/399
• US Class Current: 524/430
• 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
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• 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 1/054 Nanosized particles
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• CPC Class Codes: B22F 1/10 Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
• CPC Class Codes: B22F 1/102 Metallic powder coated with organic material
• CPC Class Codes: B22F 1/12 Metallic powder containing non-metallic particles containing lubricating or binding agents or organic material B22F1/10
• CPC Class Codes: B22F 2202/13 Use of plasma
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• 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 20/00 : Nanooptics, e.g. quantum optics or photonic crystals
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• CPC Class Codes: B82Y 30/00 : Nanotechnology for materials or surface science, e.g. nanocomposites
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• CPC Class Codes: C04B 2235/6565 : Cooling rate
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• CPC Class Codes: C04B 35/10 : based on aluminium oxide
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• CPC Class Codes: C04B 35/453 : based on zinc, tin, or bismuth oxides or solid solutions thereof with other oxides, e.g. zincates, stannates or bismuthates
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• CPC Class Codes: C04B 35/6265 : involving reduction or oxidation
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• CPC Class Codes: C04B 41/009 : characterised by the material treated
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• CPC Class Codes: C04B 41/4549 : Nanometer-sized particles
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• 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: C04B 41/90 : at least one coating being a metal
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• CPC Class Codes: C08K 3/01 : characterized by their specific function
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• CPC Class Codes: C09C 1/0081 : Composite particulate pigments or fillers, i.e. containing at least two solid phases, except those consisting of coated particles of one compound C09C1/0015, C09C1/0078 take precedence
• CPC Class Codes: C09C 1/22 : Compounds of iron C09C1/0009, C09C1/0015, C09C1/0078 take precedence
• CPC Class Codes: C09C 1/627 : Copper
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• 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
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• CPC Class Codes: H01M 6/36 : containing electrolyte and made operational by physical means, e.g. thermal cells
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Abstract

Nanocomposites from nanofillers with preferred form of whiskers, rods, plates and fibers are disclosed. The matrix composition described includes polymers, ceramics and metals. The composition disclosed include inorganic, organic and metallic. These nanocomposites are useful in wide range of applications given their unusual properties such as refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

Claims

1. A nanocomposite comprising:

a matrix;

inorganic nanofillers in the form of whiskers;

wherein the nanofillers have a composition comprising of two or more elements and a domain size less than 100 nanometers;

wherein the inorganic nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

2. The nanocomposite of claim 1, wherein the matrix comprises a ceramic or polymer.

3. The nanocomposite of claim 1 wherein the nanofillers are surface treated.

4. The nanocomposite of claim 1 wherein the nanofillers are coated.

5. The nanocomposite of claim 1 wherein the nanofillers comprise nanorods.

6. The nanocomposite of claim 1 wherein the inorganic nanofillers are mixed into the matrix at a loading above percolation limit or sufficient to provide connectivity in at least 1 dimension.

7. A product comprising the nanocomposite of claim 1.

8. The nanocomposite of claim 6 wherein the nanofillers comprises fillers with an aspect ratio greater than two.

9. A product comprising the nanocomposite of claim 6.

10. A nanocomposite comprising:

a polymer matrix;

inorganic nanofillers in the form of whiskers;

wherein the nanofillers have a composition comprising of two or more elements;

the inorganic nanofillers are mixed into the polymer matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

11. A nanocomposite comprising:

a metal matrix;

inorganic nanofillers in the form of whiskers;

the inorganic nanofillers are mixed into the metal matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

12. A nanocomposite comprising:

a matrix;

inorganic nanofillers in the form of fibers;

wherein the nanofillers have a composition comprising of two or more elements and a domain size less than 100 nanometers;

wherein the inorganic nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

13. The nanocomposite of claim 12 wherein the matrix comprises a ceramic or polymer.

14. The nanocomposite of claim 12 wherein the nanofillers are surface treated.

15. The nanocomposite of claim 12 wherein the nanofillers are coated.

16. A nanocomposite comprising:

a metal matrix;

inorganic nanofillers in the form of fibers;

wherein the nanofillers have a composition comprising of two or more elements;

wherein the inorganic nanofillers are mixed into the metal matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

17. A nanocomposite comprising:

a matrix;

uncoated inorganic nanofillers in the form of plates;

wherein the nanofillers have a domain size less than 100 nanometers;

the inorganic nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

18. The nanocomposite of claim 17 wherein the matrix comprises a ceramic or Polymer.

19. The nanocomposite of claim 17 wherein the nanofillers are surface treated.

20. A nanocomposite comprising:

a metal matrix;

inorganic nanofillers in the form of plates;

the inorganic nanofillers are mixed into the metal matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive Index, transparency to light reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

21. A nanocomposite comprising:

a matrix;

organic nanofillers comprising a form selected from the group consisting of;

whiskers, fibers and plates;

wherein the nanofillers have a domain size less than 100 nanometers;

wherein the organic nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

22. A product comprising the nanocomposite of claim 21.

23. A nanocomposite comprising:

a matrix;

metallic nanofillers comprising a form selected from the group consisting of whiskers, fibers and plates;

wherein the nanofillers have a domain size less than 100 nanometers;

wherein the metallic nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.

24. The nanocomposite of claim 23 wherein the metallic nanofillers comprise an alloy.

25. A product comprising the nanocomposite of claim 23.

26. A nanocomposite comprising:

a matrix;

nanofillers comprising a composition of two or more elements from the periodic table;

wherein at least one of the two or more elements is selected from the group consisting of aluminum, antimony, boron, bromine, carbon, chlorine, fluorine, germanium, hydrogen, indium, iodine, nitrogen, oxygen, phosphorus, selenium, silicon, sulfur, or tellurium;

wherein nanofillers comprise fillers with an aspect ratio greater than one;

wherein the nanofillers are mixed into the matrix at a loading less than 80 percent by volume to form a nanocomposite;

wherein the nanocomposite exhibits a material property that differs by more than 20% as compared with the material property exhibited by a composite of similar composition with fillers having a domain size of at least one micron; and

wherein the material property is selected from the group consisting of;

refractive index, transparency to light, reflection characteristics, resistivity, permittivity, permeability, coercivity, B-H product, magnetic hysteresis, breakdown voltage, skin depth, curie temperature, dissipation factor, work function, band gap, electromagnetic shielding effectiveness, radiation hardness, chemical reactivity, thermal conductivity, temperature coefficient of an electrical property, voltage coefficient of an electrical property, thermal shock resistance, biocompatibility, and wear rate.