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

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...

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 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.

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.

This method is anticipated to lead to higher costs.

Furthermore, the teachings do not suggest ways to produce high purity powders.

The sodium vapor process is difficult to operate, increases safety concerns, is expensive and is difficult to scale up.

It is expected that the powders produced have sodium and chloride contamination arising from the synthesis mechanism used.

The teachings are limited to producing particles that are compatible with sodium flame chemistry.

Furthermore, the teachings do not specify methods to produce complex materials such as multimetal oxides, carbides, nitrides, borides, and the like.

The process is also limited in its economic attractiveness.

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