US 7,253,226 B1 · Tractable silica sols and nanocomposites therefrom

Abstract

Disclosed are silica sols made by combining at least one hydrolysable silane, at least one organofunctional silane, at least one boron oxide compound, and a liquid, or silica sols made by combining at least one hydrolysable silane, at least one organofunctional silane, at least one acid catalyst, and a liquid to provide an intermediate sol and combining at least one base catalyst with the intermediate sol. Also disclosed are nanocomposites containing the silica sols and at least one of metal nanoparticle, metal-chalcogenide nanoparticle, metal oxide nanoparticle, and metal phosphate nanoparticle. Further disclosed are composites containing a polymer material and at least one of the silica sol and the nanocomposite.

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Claims20

Dependent claims

A method of making a silica sol comprising combining:

from about 10% to about 80% by weight of at least one hydrolysable silane,
from about 10% to about 60% by weight of at least one organofunctional silane,
from about 0.5% to about 80% by weight of at least one boron oxide compound and an optional catalyst, or effective amounts of at least two catalysts to provide the silica sol and an optional boron oxide compound, and a liquid.

A method of making a nanocomposite comprising combining:

from about 10% to about 80% by weight of at least one hydrolysable silane,
from about 10% to about 60% by weight of at least one organofunctional silane,
from about 0.5% to about 80% by weight of at least one boron oxide compound and an optional catalyst, or effective amounts of at least two catalysts to provide a host silica sol and an optional boron oxide compound,
a liquid;
and
from about 0.001% to about 80% by weight of at least one of guest metal nanoparticle, guest metal-chalcogenide nanoparticie, metal phosphate nanoparticle, guest metal oxide nanoparticle, and precursors of these guest nanoparticles.

3 more elements

A polymer composite comprising:

from about 1% to about 99.99% by weight of a polymer material;
from about 0.01% to about 99% by weight of a silica sol and/or a nanocomposite comprising at least one of metal nanoparticle, metal-chalcogenide nanoparticle, metal phosphate nanoparticle and metal oxide nanoparticle substantially uniformly dispersed within the polymer material;
wherein the silica sol is at least one of a silica sol made by combining from about 10% to about 80% by weight of at least one hydrolysable silane;
from about 10% to about 60% by weight of at least one organofunctional silane;
from about 0.5% to about 80% by weight of at least one boron oxide compound;
an optional catalyst;
and a liquid;
or a silica sol made by combining from about 10% to about 80% by weight of at least one hydrolysable silane, from about 10% to about 60% by weight of at least one organofunctional silane, at least one acid catalyst, and a liquid to provide an intermediate sol and combining at least one base catalyst with the intermediate sol to provide the silica sol;
and
wherein the nanocomposite is at least one of a nanocomposite comprising from about 0.001% to about 80% by weight of at least one of guest metal nanoparticle, guest metal-chalcogenide nanoparticle, metal phosphate nanoparticle and metal oxide nanoparticle, and from about 20% to about 99.999% by weight of the host silica sol;
a nanocomposite made by chalcogenizing a host-guest silica sol comprising from about 0.001% to about 80% by weight of at least one of guest metal-chalcogenide precursors, guest metal nanoparticles, and guest metal oxide nanoparticles and from about 20% to about 99.999% by weight of the host silica sol;
a nanocomposite made by phosphatizing a host-guest silica sol comprising from about 0.001% to about 80% by weight of at least one of guest metal phosphate precursors, guest metal nanoparticles, and guest metal oxide nanoparticles and from about 20% to about 99.999% by weight of the host silica sol;
or a nanocomposite made by oxidizing a host-guest silica sol comprising from about 0.001% to about 80% by weight of at least one of guest metal oxide precursors and guest metal nanoparticle and from about 20% to about 99.999% by weight of the host silica sol.

10 more elements

Dependencies are inferred from the claim text.

Description19,458 words

Summary462 words

#The subject invention generally relates to silica sols, silica sol hosted guest metal nanoparticles, silica sol hosted guest metal-chalcogenide nanoparticles, silica sol hosted guest metal phosphate nanoparticles, silica sol hosted guest metal oxide nanoparticles, and polymers containing the silica sols, polymers containing the silica sol hosted at least one of guest metal nanoparticles, guest metal-chalcogenide nanoparticles, guest metal phosphate nanoparticles, and guest metal oxide nanoparticles, and related methods.

#In the last century, synthetic polymers have revolutionized the way in which we live. From synthetic rubber used in tires, structural plastic used in transportation systems, to field responsive polymers used in optical and electrical devices, synthetic polymers are used everywhere. A myriad of products and components for products are made, at least in part, of a polymer material. As the uses for polymers continue to increase, it becomes more and more desirable to improve the properties of polymers.

#For example, silica, graphite, carbon black, and clay among many other materials have been incorporated into polymers in attempts to improve the properties of the resultant composites. While improvements have been realized, further improvements are desired.

Detailed description18,996 words

#The silica sols may be prepared by mixing certain amounts of at least one hydrolysable silane; at least one organofunctional silane; at least one of a boron oxide compound; and a liquid. The silica sols may be prepared by mixing certain amounts of at least one hydrolysable silane; at least one organofunctional silane; at least two catalysts; and a liquid. Dried silica sols can be prepared by removing the liquid from the silica sol.

#The nanocomposites contain silica sols, which act as a host and at least one of guest metal nanoparticle such as a noble or non-noble metal nanoparticle, metal-chalcogenide nanoparticle such as noble or non-noble metal-chalcogenide nanoparticle, and metal oxide nanoparticle such as noble or non-noble metal oxide nanoparticle. Although not wishing to be bound by any theory, it is believed that the silica sols act as hosts for individual guest metal atoms and clusters of guest metal atoms. Extensive aggregation and/or precipitation of guest metal is thereby mitigated. The host silica sols also play an important role in improving the compatibility of the resulting nanocomposites with polymer materials. The nanocomposites can be stored in a stable manner in liquid/sol form or in powder/dry form. The nanocomposites are thermally stable, thereby facilitating their use in polymer systems.

#The host silica sols contribute to the stability of the nanoparticles; that is, at least partly owing to the presence of the silica sols the nanoparticles are stable over a long period of time, may be stored in a dry state, and are compatible with polymer systems.

Facts

Application

11/202,293Filed 11 Aug 2005

Published

US 2007/0167554 A119 Jul 2007

Granted

7 Aug 2007

Term ended

1 Oct 2025

Estimated · how

20 years from earliest known nonprovisional domestic filing plus recorded patent term adjustment, including 51 days of adjustment. Maintenance-fee lapses, terminal disclaimers and statutory extensions have not been checked. The continuity chain may be incomplete; this is not an enforceability determination.

Classification6 codes

B01J 21/08
Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof: silica
B82Y 30/00
Nanotechnology for materials or surface science
C01B 33/14
Silica; Hydrates thereof, e.g. lepidoic silicic acid: colloidal silica, e.g. dispersions, gels, sols
B01J
Chemical or physical processes

Tractable silica sols and nanocomposites therefrom

Life of this patent

Tractable silica sols and nanocomposites therefrom

Life of this patent

Life of this patent

Abstract

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Drawings

Claims20

Description19,458 words

Drawings

Classification6 codes

Life of this patent

Description19,458 words