High purity nanoscale metal oxide powders and methods to produce such powders

a technology of nanoscale metal oxide and fine powder, which is applied in the direction of lanthanide oxide/hydroxide, chemical/physical/physical-chemical processes, energy-based chemical/physical/physical-chemical processes, etc., can solve the problems of failure or defect of electronic and other applications, low volume, and high cost of methods, and achieve high purity and high volume

Inactive Publication Date: 2005-03-24
PPG IND OHIO INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

Briefly stated, the present invention involves a method of producing high purity nanoscale powders in which the purity of powders produced by the method exceeds 99.99%. Fine powders produced are of size preferably less than 1 micron, and more preferably less than 100 nanometers. Methods fo

Problems solved by technology

Furthermore, since they represent a whole new family of material precursors where conventional coarse-grain physiochemical mechanisms are not applicable, these materials offer unique combinations of properties that can enable novel and multifunctional components of unmatched performance.
Impurities cause failures or defects in electronic and other applications.
These methods are expensive, slow, low volume, and difficult when purities greater than 99.99% are desired.
They do not teach how to reach product purities greater than 99.9%, and their process is expected to be expensive.
The process is not suitable for production of oxides, carbides, and many other compounds.
T

Method used

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  • High purity nanoscale metal oxide powders and methods to produce such powders
  • High purity nanoscale metal oxide powders and methods to produce such powders
  • High purity nanoscale metal oxide powders and methods to produce such powders

Examples

Experimental program
Comparison scheme
Effect test

example 1

Magnesium Oxide

Magnesium acetate was dissolved in high purity water and pumped as a liquid into a plasma reactor. To ensure complete oxidation, pure oxygen was fed into the process. The core temperature of the plasma was greater than 6000° C., while the outer edge temperature was estimated to be greater than 3000° C. The plasma was produced using a DC arc and argon as the plasma gas. The precursor completely vaporized when it interacted with the plasma. The metal vapor oxidized completely. The vapor was slightly cooled to encourage the formation of nanopowder. The nanopowder containing stream was quenched in a converging diverging nozzle (to >103 ° C. / sec) in flowing oxygen. The powder was harvested using membrane bags and a venturi cyclone fed with compressed air for suction effect. The collected powder was high purity magnesium oxide (MgO) with surface area greater than 100 m2 / gm and mean size less than 10 nm. Over a two hour run, over 100 grams of powder were harvested. This ex...

example 2

Magnesium Oxide

In another run, magnesium acetate (Reagent Grade 1271R, Shepherd Chemical Company, Cincinnati, Ohio, USA) was dissolved in high purity water and pumped as a liquid into a plasma reactor. The feed had the following impurities on metal basis (K: 35 ppm, Na: 203 ppm, Fe: 88 ppm, Ca: 27 ppm, Ba: <9 ppm, Mn: 53 ppm, Sr: <9 ppm). To ensure complete oxidation, pure oxygen was fed into the process at a faster rate than in Example 1. The core temperature of the plasma was greater than 6000° C., while the outer edge temperature was estimated to be greater than 3000° C. The plasma was produced using a DC arc and argon as the plasma gas. The precursor completely vaporized when it interacted with the plasma. The vapor oxidized completely. The vapor was slightly cooled to encourage the formation of nanopowder. The nanopowder containing stream was quenched in a converging diverging nozzle (to >103 ° C. / sec) in flowing oxygen. The powder was harvested using membrane bags ...

example 3

Indium Tin Oxide

Indium octoate and tin octoate were mixed in a specified ratio by metal basis. Indium-tin-oxide (ITO) powders with grain size less than 20 nm were produced using the process of Example 1. This example illustrated that fine powders, and more specifically nanopowders, of high purity complex multimetal oxides can be manufactured from fluids. Such high purity multimetal oxides are desired in numerous applications such as, but not limited to, coatings for EMI shielding, electronic, electromagnetic, device, thermal, catalytic, photonic, optical, electrochemical, chemical, sensor, other films / coatings, instrumentation, sputtering and biomedical applications.

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Abstract

A method of producing high purity nanoscale powders in which the purity of powders produced by the method exceeds 99.99%. Fine powders produced are of size preferably less than 1 micron, and more preferably less than 100 nanometers. Methods for producing such powders in high volume, low-cost, and reproducible quality are also outlined. The fine powders are envisioned to be useful in various applications such as biomedical, sensor, electronic, electrical, photonic, thermal, piezo, magnetic, catalytic and electrochemical products.

Description

BACKGROUND OF THE INVENTION 1. Related Applications This application is a divisional application of co-pending U.S. Pat. No. 09 / 638,977 filed Aug. 15, 2000, which claims priority to U.S. provisional patent application serial No. 60 / 182,692 entitled “Very High Purity Fine Powders and Methods to Produce Such Powders” filed Feb. 15, 2000, the specifications of which are incorporated herein by reference. 2. Field of the Invention The present invention relates, in general, to high purity powders, and, more particularly, to high purity fine powders and methods to produce high purity fine powders. 3. Relevant Background Powders are used in numerous applications. They are the building blocks of electronic, telecommunication, electrical, magnetic, structural, optical, biomedical, chemical, thermal, and consumer goods. On-going market demand for smaller, faster, superior and more portable products has resulted in miniaturization of numerous devices. This, in turn, has demanded miniaturi...

Claims

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Application Information

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IPC IPC(8): B01J19/08B22F1/054B22F9/12B22F9/14B22F9/30C01B13/14C01B13/20C01B21/06C01B21/082C01B31/36C01F5/06C01F17/218C01F17/235C01G1/02C01G19/00C01G25/00C01G49/04C01G49/06C01G49/08C01G53/04C04B41/89
CPCB01J19/088B01J2219/0886C04B2235/721C04B2235/72B01J2219/0894B22F1/0018B22F9/12B22F9/14B22F9/30B22F2999/00B82Y30/00C01B13/14C01B13/20C01B21/06C01B21/0828C01B31/36C01F5/06C01F17/0043C01G1/02C01G19/00C01G25/00C01G49/04C01G49/06C01G49/08C01G53/04C01P2002/34C01P2002/52C01P2004/54C01P2004/61C01P2004/62C01P2004/64C01P2006/12C01P2006/80C04B35/62665C04B41/89C04B2235/3205C04B2235/3206C04B2235/3208C04B2235/3215C04B2235/3224C04B2235/3227C04B2235/3229C04B2235/3236C04B2235/3249C04B2235/3272C04B2235/3282C04B2235/3286C04B2235/3293C04B2235/3427C04B2235/3804C04B2235/3817C04B2235/3826C04B2235/3852C04B2235/3895C04B2235/449C04B2235/5409C04B2235/5445C04B2235/5454B22F2202/13C01B32/956C01B32/977C01F17/235C01F17/218
Inventor YADAV, TAPESHPFAFFENBACH, KARL
Owner PPG IND OHIO INC
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