JP2007534586A - 液体送出フレーム溶射によるナノ粒子の修飾 - Google Patents
液体送出フレーム溶射によるナノ粒子の修飾 Download PDFInfo
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- JP2007534586A JP2007534586A JP2007500814A JP2007500814A JP2007534586A JP 2007534586 A JP2007534586 A JP 2007534586A JP 2007500814 A JP2007500814 A JP 2007500814A JP 2007500814 A JP2007500814 A JP 2007500814A JP 2007534586 A JP2007534586 A JP 2007534586A
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- alumina
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Abstract
【解決手段】 ナノおよびミクロンサイズの金属酸化粒子および混合した金属酸化物粒子を、約400℃以上で、2000℃未満の間の高温領域に射出して、特定の性質が実質的に維持されている粒子または被覆として回収される。この粒子は、相、形態、組成、および粒径分布のうちの少なくとも一つを修飾して、液状の金属酸化物先駆物質を同時に射出することによって、これらの特徴を更に変化させることができる。
【選択図】 なし
Description
本発明は、2004年2月27日に出願した米国暫定出願第60/548,729号の利益を主張する。この出願はここに含まれている。
本発明は、AFOSR契約番号第F49620−03−1−0389の政府支援のもとになされた。政府は、本発明について所定の権利を有する。
1.発明の属する技術分野
本発明は、液体送出フレーム溶射技術による中温フレームへの射出による金属酸化物粒子の修飾に関する。
皮膜の製造用に粒子を溶融させる、あるいはむしろ蒸発させるために、約2000℃の高温のプラズマまたはフレーム中に粒子を供給している。しかしながら、この技術は、粒状の特性を維持する一方で、例えば、結晶相、アモルファス相、あるいはこの両方に相が変わり、あるいは、ミクロン範囲の粒子、好ましくはナノメートルサイズの粒子から中空またはコア/シェル粒子形態ができる低温処理については、あまり知られていない。
400℃から2000℃未満の温度でフレームにマイクロ粒子、好ましくはナノ粒子を導入して、新規な組成の物質を作ることができること、および、これまで可能でなかった有益な相転移を行うのに使用できることは、驚くべき発見であった。変形した結晶層を有する粒子に加えて、金属で被覆した金属酸化物粒子を含めてその表面に付着した組成が異なる粒子を形成することができる。この生成物は、高密度に焼成したセラミック材料、新規触媒、光電子におけるアプリケーション、その他を含めて広範囲に使用することができる。
従って、本発明は、広い意味では、液体送出フレーム溶射熱分解によって高温ゾーン(フレーム)に第1の組成と形態を有する粒子を射出することによって、異なる組成及び/又は形態を有する粒子を得る粒子生成プロセスに関する。このようにして得た粒子は、特定の特徴をある程度維持する粒子状態にある間に、回収するか、又は「ターゲット」または「基板」に衝突させる。言い換えると、この粒子はターゲットに衝突したときに、「スプラット」するまたは溶融する状態にまで溶けず、滑らかな、あるいはいくらか不規則な連続コーティングを形成するが、不連続粒子の形で強力に付着する。
チタナトレンイソプロポキシド(titanatrane isopropoxide)またはTyzor TE[(Me2CHOTi(OCH2CH2)3N)]をDupont社から購入した。エタノールを一般的な源から購入し、受領したときに使用した。γ−アルミナパウダをDegussa社から受け取って、δ−アルミナパウダは、アルマトレン、Al(OCH2CH2)3NのLF−FSPで準備した。
被覆された、あるいは同時反応した、あるいは同時射出した、または連続的に反応させたナノパウダまたはミクロンサイズのパウダの製造に用いるシステムはユニークである。一旦懸濁させたパウダを、ポンプでくみ出して、エーロゾル化中に懸濁粒子を摩食しないポンプシステムを用いてエーロゾル化する必要がある。このシステムには、超音波アトマイザや、ベルヌーイのミスタまたはその他の同様のミスタがあり、パウダサスペンションを酸素あるいは空気、または約50ミクロン未満の液滴が発生する不活性ガスと混合する。代替的に、パウダ及び/又は先駆物質は、液状または気体サスペンションとしてフレームへ順次射出することができる。
典型的には、懸濁媒体中に同時射出したまたは連続射出した先駆物質を伴う、あるいは伴わない懸濁粒子の、2−20重量%セラミック収量溶液を、酸素または空気を用いて超音波アトマイザで約30ml/分霧化して、エアロゾルを発生させる。これは、デバイスの点火室中のメタン/酸素パイロットトーチを介して点火される。代替的に、このパウダを、気体中の飛沫同伴を介してフレーム内に別個に導入することもできる。<2000℃の温度で燃焼が生じ、次の例で述べるように選択された生成物と、ガス状の副産物を生成する。燃焼室と300℃の回収ポイント(約1.5m)間の、>500℃/分といった急激な温度勾配は、パウダが燃焼ゾーンから、例えば、インラインの半径方向の圧力ブロワを用いて<700cfmの空気流によって比較的高速で取り去られてしまうので、急な冷却が生じる。急速な冷却は、消散可能なパウダと、小さい粒径の維持に必要な粒子ネッキングの最小化を伴う。パウダは、下流側で、電気集塵機(ESPs)あるいはバッグハウスまたはサイクロンフィルタに回収される。
約46gのδ−アルミナを、4リットルの50%EtOH/50%ButOH中で2時間、超音波処理した。これに、EtOHに溶かしたCr(O2CCH2CH3)3先駆物質(0.1重量%のCr2O3固体添加量)を加えた。結果としてできた先駆物質混合物である、92:8重量%のAl2O3:Cr2O3を酸素でエアロゾル化して、下流側のESPsで回収したパウダを25g/hでメタントーチを用いて発火させた。
4リットルのEtOH/ButOHが50/50中の、粒子径が20−40nmで表面積が60m2/gのδ−アルミナ40gの1重量%懸濁液を、4L/hのレートでLF−FSPにかけた。結果としてのパウダは、α−アルミナとθ−アルミナの混合物に変換される。
4リットルのEtOH/ButOHが50/50中の、粒子サイズが<20nmで表面積が約110m2/gのγ−アルミナ40gの1重量%懸濁液を、4L/hのレートでLF−FSPにかけた。結果としてのパウダは、α−アルミナとθ−アルミナの混合物に変換される。
α−アルミナパウダ(15g)をTyzor TEと混合して、80モル%アルミナ−20モル%チタニアの調合物を作った。400mlのEtOHを加えて、この溶液を超音波処理によって5分間分散させ、次いで、2500mlのEtOHを加えて、少なくとも30分間20℃で攪拌した。次いで、LF−FSPを行い、結果物の粒子は、ルチルで被覆したα−アルミナでできていた。
α−アルミナパウダ(15g)をTyzor TEと混合して、80モル%アルミナ−20モル%チタニアの調合物を作った。400mlのEtOHを加えて、この溶液を超音波処理によって5分間分散させ、次いで、2500mlのEtOHを加えて、少なくとも30分間20℃で攪拌した。次いで、LF−FSPを行い、結果物の粒子は、α−アルミナとこれまでにないチタニアドープ相からなるものであった。
δ−アルミナパウダ(2g)をTyzor TEと混合して、モル%アルミナ−85モル%チタニアの調合物を作った。400mlのEtOHを加えて、この溶液を超音波処理によって5分間分散させ、次いで、1250mlのnBuOHと1250mlのEtOHを加えて、20℃で少なくとも30分間攪拌した。XRDで分析した生成物は、ナノパウダを同時射出することなく先駆物質のLF−FSPだけで生成したものとよく似たアルミナのみをドープしたチタニアであることがわかった。
上記のとおり製造したα−アルミナナノパウダ(75重量%相ピュア)15gを、4リットルの50/50(体積)のEtOH/nBuOH溶液中に分散させた。125gのイットリウムプロピオネート(4重量%セラミック)を加えた。トータルのセラミック添加量は、0.5重量%であり、75重量%のν−Al2O3:25重量%のイットリウムプロピオネートとしてのY2O3であった。この混合物をLF−FSPで20g/hのレートで処理した。
Degussa社のδ−アルミナ、15gを4リットルの50/50(体積)のEtOH/nBuOH溶液中に分散させた。125gのイットリウムプロピオネート(4重量%セラミック)を加えた。トータルのセラミック添加量は、75重量%のν−Al2O3:25重量%の(イットリウムプロピオネートとしての)Y2O3比で0.5重量%であった。この混合物をLF−FSPで、約20g/hで処理した。
δ−アルミナ、15gを4リットルの50/50(体積)のEtOH/nBuOH溶液中に分散させた。41.3gのイットリウムプロピオネート(12重量%セラミック)を加えた。トータルのセラミック添加量は、75重量%のν−Al2O3:25重量%のネオジミウムプロピオネートとしてのNd2O3比で、0.5重量%であった。この混合物をLF−FSPで、約20g/hで処理した。生成物は、純粋なNdAlO3に見えた。
12重量%のセラミックと、15gのδ*−Al2O3パウダを有するNiプロピオネート先駆物質とを機械的に混合してコアシェルパウダを作り、LF−FSPを行った。
25gのクレイを、EtOH:H2Oと上述したアルミナミリング媒体100gとを50:50にしたのもを180mlと共に250mLのPVPボトルに入れて、クレイ懸濁液先駆物質を準備した。
クレイ懸濁液先駆物質を、25gのクレイを、MeOH:H2Oと上述したアルミナミリング媒体100gとを50:50にしたものを180mlと共に250mLのPVPボトルに入れて準備した。
25gのクレイを、MeOH:H2Oと上述したアルミナミリング媒体100gとを50:50にしたもの180mlと共に250mLのPVPボトルに入れてクレイ懸濁液先駆物質を準備した。
25gのクレイを、MeOH:H2Oと上述したアルミナミリング媒体100gとを50:50にしたものを180mlと共に250mLのPVPボトルに入れてクレイ懸濁液先駆物質を準備した。
ガラス、セラミック、および金属コンポネントの上のナノ粒子コーティングは、所望の基板を例1または上述したその他の例からの生成物ストリームに、温度が粒子の特性を有意に変更することなく粒子を基板表面に接着させるように、晒すことによって作ることができる。結果物としてのコーティングは、耐磨耗性であり、触媒的に活性であり、耐腐食性であり、第2のコーティング材料に接着し、あるいは、似ていない材料に結合することができる。
Claims (13)
- 金属酸化物と100μm未満の数平均粒子径を有する混合金属酸化物を具える粒子の修飾プロセスにおいて:
a)400℃以上で2000℃未満の温度の高温ゾーンに前処理を行った粒子を射出するステップと;
b)選択的に、一またはそれ以上の金属酸化物先駆物質の化合物を具える液状組成物を同時に射出するステップと;
c)急速に粒子を冷却して、生成粒子、または、生成粒子のコーティングを得るステップと、組成、相、形態、粒子サイズ、または粒子サイズの分布のうちの少なくとも一つを修飾するステップと;
を具えることを特徴とするプロセス。 - 請求項1に記載のプロセスにおいて、前記温度が600℃から1400℃の間であることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、金属酸化物先駆物質組成物が同時に射出されることを特徴とするプロセス。
- 請求項3に記載のプロセスにおいて、前記金属酸化物先駆物質が、前処理をした粒子の射出時点に対して、連続的に射出されることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、最小限二つの異なるタイプの粒子が同時に射出され、回収された生成粒子が、実質的に同時射出されたタイプの異なる粒子のそれぞれを構成物質を含有する単一のタイプの粒子であることを特徴とするプロセス。
- 請求項3に記載のプロセスにおいて、前記ステップc)で回収された生成粒子は、前記前処理を行った粒子の同じ金属酸化物と、前記金属酸化物の先駆物質を熱分解して得た金属酸化物を具える均一の組成物である粒子を具えることを特徴とするプロセス。
- 請求項3に記載のプロセスにおいて、ステップc)で回収した前記生成粒子が少なくとも2相の粒子を具え、少なくとも一相が前記金属酸化物先駆物質を熱分解して得た金属酸化物を具えることを特徴とするプロセス。
- 請求項3に記載のプロセスにおいて、前記生成粒子が、前記金属酸化物先駆物質を熱分解して得られた金属酸化物で強化した外側相を具えることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前処理した粒子が、γ−アルミナ、δ−アルミナ、θ−アルミナ、またはこれらの混合物であり、ステップc)で回収した前記粒子がα−アルミナか、あるいは、前記前処理した粒子のα―アルミナ成分に対してα―アルミナで強化したものであることを特徴とするプロセス。
- 請求項1に記載のプロセスにおいて、前記生成粒子が、ステップc)で少なくとも部分的に冷却した後に、ターゲット基板に衝突し、この基板に接着して、実質的に、その粒子の特徴を維持すると共に、連続的コーティングを形成しないことを特徴とするプロセス。
- 高密度焼成アルミナ製品の製造方法において:
1)請求項9のプロセスによって、α−アルミナを具える焼成可能な生成粒子を作るステップと;
2)前記焼成可能な粒子からグリーンボディを作るステップと;
3)前記グリーンボディを焼成して、理論的に完全に密なアルミナの60%より大きい密度を有するアルミナ製品を製造するステップと;
を具えることを特徴とする方法。 - 請求項1に記載のプロセスにおいて、前記前処理した粒子が、クレイまたはアッシュ粒子を具えることを特徴とする方法。
- 請求項12に記載のプロセスにおいて、クレイ粒子が、前処理した粒子であり、生成粒子が中空状の球を具えることを特徴とする方法。
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