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  Gas dispersion manufacture of nanoparticulates, and nanoparticulate-containing products and processing thereofUSPTO Application #: 20070290384Title: Gas dispersion manufacture of nanoparticulates, and nanoparticulate-containing products and processing thereof Abstract: In one aspect, the present invention relates to a method of making multi-phase particles that include nanoparticulates and matrix, which maintains the nanoparticulates in a dispersed state. A flowing gas dispersion is generated that includes droplets of a precursor medium dispersed in a gas phase. The precursor medium contains liquid vehicle and at least a first precursor to a first material and a second precursor to a second material. The multi-phase particles are formed from the gas dispersion by removing at least a portion of the liquid vehicle from the droplets of precursor medium. The nanoparticulates in the multi-phase particles include the first material and the matrix in the multi-phase particles includes the second material. (end of abstract)
Agent: Marsh, Fischmann & Breyfogle LLP - Aurora, CO, US Inventors: Toivo T. Kodas, Mark J. Hampden-Smith, Klaus Kunze, David E. Dericotte, Karel Vanheusden, Aaron D. Stump USPTO Applicaton #: 20070290384 - Class: 264005000 (USPTO) Related Patent Categories: Plastic And Nonmetallic Article Shaping Or Treating: Processes, Formation Of Solid Particulate Material Directly From Molten Or Liquid Mass (e.g., Liquid Comminuting) The Patent Description & Claims data below is from USPTO Patent Application 20070290384. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to nanoparticulate materials, products containing and made using nanoparticulate materials, and methods of making and processing nanoparticulate materials. BACKGROUND OF THE INVENTION [0002] Nanoparticulate materials, and methods for making nanoparticulate materials, have been the subject of recent interest and research because of the advantages provided by nanoparticulate materials over larger sized particulate materials. One advantage of nanoparticulates is increased surface area, which is useful in a variety of applications, including catalyst, electrocatalyst, absorbent, chemical separations and bio-separation applications. Nanoparticulates are also useful in formulations of inks, pastes and tapes that are used in depositing thin or thick films, such as optically transparent conductors for use in displays, magnetic coatings for storage media and printed circuitry for electronic applications. Inks and pastes with nanoparticulates have improved rheology characteristics (e.g., flowability), which allow thinner layers to be applied and allow deposition of features with smaller dimensions. Lighting applications also benefit from the properties of nanoparticulate materials; for example, semiconductor nanoparticulates, in addition to other uses, are useful because of their "quantum dot effect," which allows the luminescent color of a semiconductor nanoparticulate to be tailored according to the size of the nanoparticulate. In addition to the examples above, nanoparticulate materials are being used, or considered for use, in many other applications including pharmaceutical formulations, drug delivery applications, medial diagnostic aids, abrasives, pigments, phosphors for lighting, dental glasses, polymeric fillers, thermal interface materials and cosmetics. [0003] As a result of the large number of applications for nanoparticulate materials, a variety of methods have been developed for making and processing nanoparticulates. One common problem faced by these methods is the tendency of the nanoparticulates to agglomerate because of their high surface area. Once the nanoparticulates have agglomerated, often they do not provide the same advantages achieved when the individual nanoparticulates are in a dispersed state. Consequently, the tendency of nanoparticulates to agglomerate makes the forming, processing, handling, transporting and use of nanoparticulates problematic. Complicating matters is that separating or redispersing nanoparticulates once they have agglomerated is difficult to do. [0004] Thus, there is a need for additional methods of forming, processing, handling, transporting and using nanoparticulates and new nanoparticulate products that alleviate some or all of these problems. SUMMARY OF THE INVENTION [0005] With the present invention, problems with agglomeration that may be encountered during manufacture, processing, handling and using nanoparticulates may be addressed through manufacture and/or processing of nanoparticulates in a dispersed state within multi-phase particles in which the nanoparticulates are maintained in the dispersed state by matrix. [0006] A first aspect of the invention involves a method for making nanoparticulates, with the method including generating a flowing gas dispersion containing droplets of a precursor medium dispersed in a gas phase, removing liquid vehicle from the droplets of the gas dispersion, and forming the multi-phase particles. In one implementation of this first aspect, the multi-phase particles are formed in the gas dispersion under controlled conditions. In variation of this implementation, the controlled conditions include not permitting the average stream temperature of the gas dispersion to exceed a melting temperature for more than a short time, such as no longer than 10 seconds. In variation of this implementation, a reducing agent is used to promote formation of nanoparticulate material. In another implementation this aspect, first particles are formed in the gas phase and then the first particles are modified to form second particles that are in the multi-phase form including the nanoparticulates and the matrix. In one variation of this implementation, the conversion to the second particles occurs in the gas dispersion. In another variation of this implementation, the conversion to the second particles occurs after the first particles have been separated from the gas dispersion. In another implementation of this first aspect, the multi-phase particles are formed in the gas dispersion and collected from the gas dispersion directly into a liquid medium. [0007] A second aspect of the invention involves processing of the multi-phase particles, or portions thereof. In one implementation of this second aspect, the processing involves decomposing the multi-phase particles in a liquid medium to release the nanoparticulates for dispersion in the liquid medium. In one variation of this implementation, the processing involves surface-modifying the nanoparticulates. In another variation of this implementation, the processing involves, after releasing the nanoparticulates, fixedly dispersing the nanoparticulates in a composite structure with a different matrix. In another implementation of this second aspect, the processing involves modifying at least one of the matrix and the nanoparticulates while the nanoparticulates remain in the dispersed state of the multi-phase particles. In one particular embodiment, a portion of the matrix is removed while retaining nanoparticulates in the dispersed state. In another implementation of this second aspect, multi-phase particles are subjected to treatment in a liquid medium. In one variation of this implementation, the solutes are removed from the liquid medium to reduce the concentration of the solutes in the liquid medium. In one variation of this implementation, the solutes are separated by passage through a membrane. This second aspect of the invention may be combined with the first aspect of the invention to make the multi-phase particles and then process the multi-phase particles, or portions thereof. [0008] A third aspect of the invention involves particulate product comprising the multi-phase particles. In one implementation of this aspect, the multi-phase particles a portion of the matrix is selectively removable relative to another portion of the matrix. In one variation of this implementation, the matrix includes at least two different materials, with one being selectively removable relative to the other. In another implementation of this aspect, the multi-phase particles comprise nanoparticulates of at least two different compositions. In another implementation of this aspect, the multi-phase particles include a surface-modifying material, and the multi-phase particles are decomposable to release the nanoparticulates with surface modification of the nanoparticulates through association with the surface-modifying material. The first and/or second aspects of the invention are useful for making multi-phase particles of the third aspect of the invention. [0009] These aspects, implementations and variations, and other aspects, implementations and variations of the inventions are discussed below. BRIEF DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 is a generalized process block diagram of one embodiment of the method of the present invention involving preparation of multi-phase particles including dispersed nanoparticulates and matrix. [0011] FIG. 2 generally illustrates features of a multi-phase particle manufacturable using the method of the present invention. [0012] FIG. 3 is a generalized process block diagram of one embodiment of the method of the present invention including a decomposing particles step. [0013] FIG. 4 is a generalized process block diagram of one embodiment of the method of the present invention including a modifying nanoparticulates step. [0014] FIG. 5 is a generalized process block diagram of one embodiment of the method of the present invention including a modifying nanoparticulates step followed by a decomposing particles step. [0015] FIG. 6 is a generalized process block diagram of one embodiment of the method of the present invention including a modifying nanoparticulates step preceded by a decomposing particles step. [0016] FIG. 7 is a generalized process block diagram of one embodiment of the method of the present invention including two modifying nanoparticulates steps, one following and one preceding a decomposing particles step. [0017] FIG. 8 is a generalized process block diagram of one embodiment of the method of the present invention including a modifying matrix step. [0018] FIG. 9 is a generalized process block diagram of one embodiment of the method of the present invention including a decomposing particles step, a separating nanoparticulates step and a dispersing nanoparticulates step. [0019] FIG. 10 is a generalized process block diagram of one embodiment of the method of the present invention including a decomposing particles step and a forming composite structure step. [0020] FIG. 11 is a generalized process block diagram of one embodiment of the method of the present invention including a collecting particles step. Continue reading... Full patent description for Gas dispersion manufacture of nanoparticulates, and nanoparticulate-containing products and processing thereof Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Gas dispersion manufacture of nanoparticulates, and nanoparticulate-containing products and processing thereof patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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