Moderately Dispersed Nano Dy2O3 for High-Yield Size Control
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Solution Overview
Problem
Existing methods struggle to achieve high-yield synthesis of nano-Dy2O3 particles with precise control over morphology, size, and dispersion without resorting to grinding, as high precursor concentrations lead to undesired particle growth.
Innovation Solution
A process involving mixing dysprosium salt, a chelating agent, and a polymeric additive in water, followed by heating to form a precipitate and calcining, which produces moderately dispersed Dy2O3 particles with regular morphology and narrow size distribution without grinding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high precursor concentrations are used to achieve high yield synthesis, then productivity is improved, but particle size control deteriorates due to Ostwald ripening and oriented attachment growth
Solution Approach 1:
The patent introduces a polymeric additive as an intermediary substance that adsorbs onto particle surfaces and provides steric stabilization. This mediator prevents particle aggregation and Ostwald ripening even at high precursor concentrations, enabling both high yield and precise particle size control. The polymer acts as a physical barrier that maintains particle dispersion throughout the synthesis process.
Solution Approach 2:
The patent changes the chemical parameters of the synthesis system by introducing specific polymeric additives with controlled molecular weights and functional groups. This parameter change fundamentally alters the growth kinetics and thermodynamics of particle formation, allowing high precursor concentrations to be used without triggering unwanted growth mechanisms. The polymer concentration and type are optimized to match the precursor concentration level.
2Manufacturing precision
If low precursor concentrations are used to maintain particle dispersion, then manufacturing precision is improved, but productivity deteriorates due to low yield
Solution Approach 1:
The polymeric additive serves as a mediator that enables high precursor concentrations to be used while maintaining particle dispersion. Without this intermediary, high concentrations would inevitably lead to aggregation. The polymer allows the system to decouple precursor concentration from particle aggregation, enabling both high productivity and good dispersion simultaneously.
Solution Approach 2:
The patent applies preliminary anti-action by adding the polymeric stabilizer before particle formation begins. This pre-established protective layer prevents aggregation from occurring in the first place, rather than attempting to break up aggregates after they form. The polymer is present from the outset to counteract any tendency toward aggregation that arises from high precursor concentrations.
3Length of moving object
If grinding is used to reduce particle size, then particle size is improved, but device complexity increases due to additional processing steps
Solution Approach 1:
The patent replaces the mechanical grinding system with a chemical synthesis system that directly produces particles at the desired size. Instead of using mechanical force to break down large particles, the process uses controlled chemical precipitation and growth mechanisms to form small particles directly. This substitution eliminates all grinding equipment and associated processing steps while achieving the same or better particle size control.
Solution Approach 2:
The patent performs preliminary action by controlling particle nucleation and growth during the synthesis process itself, rather than performing size reduction after particle formation. The polymeric additive and controlled precipitation conditions ensure that particles form at the target size from the beginning, eliminating the need for subsequent size reduction operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process enables large-scale production of Dy2O3 particles with high yield and controlled size distribution, maintaining discrete and well-dispersed particles, suitable for applications in ceramics, glass, phosphors, lasers, and multilayer ceramic capacitors.
Implementation Method 1
mixing a dysprosium salt, polymeric additive, and chelating agent in water to provide a dysprosium precursor solution
Implementation Method 2
heating the dysprosium precursor solution to form a precipitate
Implementation Method 3
calcining the precipitate to provide moderately dispersed Dy2O3 particles
Data Source
AI summary
Dy2O3 particles of a nanoparticle scale have beneficial properties for ceramic and electronic uses. Disclosed herein are moderately dispersed Dy2O3 particles having regular morphology and lateral size ranging from about 10 nm to 1 μm. The Dy2O3 particles may exhibit a narrow particle size distribution such that the difference between D10 and D90 is about 0.1 μm to 1 μm. Further disclosed are processes of producing these moderately dispersed Dy2O3 particles. These processes do not include grinding to obtain the particles. Also disclosed herein are uses for these Dy2O3μ particles.