U.S. patent application number 11/147566 was filed with the patent office on 2005-10-20 for ultraviolet light block and photocatalytic materials.
This patent application is currently assigned to NanoGram Corporation. Invention is credited to Bi, Xiangxin, Kambe, Nobuyuki.
Application Number | 20050232878 11/147566 |
Document ID | / |
Family ID | 25505994 |
Filed Date | 2005-10-20 |
United States Patent
Application |
20050232878 |
Kind Code |
A1 |
Kambe, Nobuyuki ; et
al. |
October 20, 2005 |
Ultraviolet light block and photocatalytic materials
Abstract
Nanoscale UV absorbing particles are described that have high UV
absorption cross sections while being effectively transparent to
visible light. These particles can be used to shield individuals
from harmful ultraviolet radiation. These particles can also be
used in industrial processing especially to produce solid state
electronic devices by creating edges of photoresist material with a
high aspect ratio. The UV absorbing particles can also be used as
photocatalysts that become strong oxidizing agents upon exposure to
LV light. Laser pyrolysis provides an efficient method for the
production of suitable particles.
Inventors: |
Kambe, Nobuyuki; (Menlo
Park, CA) ; Bi, Xiangxin; (San Ramon, CA) |
Correspondence
Address: |
Patterson, Thuente, Skaar & Christensen, P.A.
4800 IDS Center
80 South 8th Street
Minneapolis
MN
55402-2100
US
|
Assignee: |
NanoGram Corporation
|
Family ID: |
25505994 |
Appl. No.: |
11/147566 |
Filed: |
June 8, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11147566 |
Jun 8, 2005 |
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09566476 |
May 8, 2000 |
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09566476 |
May 8, 2000 |
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08962515 |
Oct 31, 1997 |
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6099798 |
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Current U.S.
Class: |
424/59 |
Current CPC
Class: |
Y10T 428/2993 20150115;
Y10T 428/8305 20150401; A61K 8/19 20130101; H01J 61/35 20130101;
Y10S 428/913 20130101; B82Y 5/00 20130101; A61K 8/29 20130101; H05K
3/0076 20130101; H01J 61/40 20130101; A61Q 17/04 20130101; A61K
2800/413 20130101; A61K 8/27 20130101; F21V 3/10 20180201; Y10T
428/2982 20150115 |
Class at
Publication: |
424/059 |
International
Class: |
A61K 007/42 |
Claims
What is claimed is:
1. A method of producing a UV absorbing layer, the method
comprising applying a layer of particles to a substantially
transparent substrate, the particles comprising metal oxide and
having an average particle diameter from about 5 nm to about 100
nm, wherein the particles have a diameter distribution such that at
least about 95 percent of the particles have a diameter greater
than about 40 percent of the average diameter and less than about
160 percent of the average diameter.
2. The method of claim 1 wherein the applying of the layer of
particles comprises coating with a particle dispersion.
3. The method of claim 1 wherein the applying of the layer of
particles comprises directly depositing particles from a stream of
particles.
4. The method of claim 1 wherein the applying of the layer of
particles comprises spray coating.
5. The method of claim 1 wherein the applying of the layer of
particles comprises spin coating.
6. The method of claim 1 wherein the substrate comprises a
silicon-based glass.
7. The method of claim 1 wherein the substrate comprises an organic
polymer.
8. The method of claim 1 wherein the metal oxide comprises
TiO.sub.2.
9. The method of claim 1 wherein the metal oxide comprises ZnO or
ZnO.sub.2.
10. The method of claim 1 wherein the metal oxide comprises
CeO.sub.2.
11. The method of claim 1 wherein the particles have a diameter
distribution such that at least about 95 percent of the particles
have a diameter greater than about 60 percent of the average
diameter and less than about 140 percent of the average
diameter.
12. A method of forming a transparent material with reduced UV
transmission comprising forming the material with particles
dispersed within the material, the particles comprising metal oxide
and having an average particle diameter from about 5 nm to about
100 nm.
13. The method of claim 12 wherein the transparent material
comprises a silicon-based glass.
14. The method of claim 12 wherein the transparent material
comprises an organic polymer.
15. The method of claim 12 wherein the transparent material
comprises high density polyethylene or polyester.
16. The method of claim 12 wherein metal oxide comprises
TiO.sub.2.
17. The method of claim 12 wherein the particles have a diameter
distribution such that at least about 95 percent of the particles
have a diameter greater than about 40 percent of the average
diameter and less than about 160 percent of the average
diameter.
18. A method for forming a photoresist material, the method
comprising mixing particles within a UV-sensitive polymer material,
the particles comprising metal oxide and having an average particle
diameter from about 5 nm to about 500 nm.
19. The method of claim 18 wherein the particles comprise
TiO.sub.2, ZnO, ZnO.sub.2 or CeO.sub.2.
20. The method of claim 18 wherein the particles have a diameter
distribution such that at least about 95 percent of the particles
have a diameter greater than about 40 percent of the average
diameter and less than about 160 percent of the average
diameter.
21. The method of claim 18 wherein the particles have an average
particle diameter from about 5 nm to about 150 nm.
22. The method of claim 18 wherein the particles have an average
particle diameter from about 5 nm to about 100 nm.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of copending U.S. patent
application Ser. No. 09/566,476 to Kambe et al., entitled
"Ultraviolet Light Block And Photocatalytic Materials," which is a
continuation of U.S. Pat. No. 6,099,798 to Kambe et al., entitled
"Ultraviolet Light Block And Photocatalytic Materials," both of
which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to metal oxide particles that
are effective at absorbing ultraviolet light for use in UV blocks
and photocatalytic materials. The invention further relates to
methods for the production of the metal oxide particles.
BACKGROUND OF THE INVENTION
[0003] While ultraviolet light can be useful in commercial
processing, contact with ultraviolet light has a detrimental effect
on biological organisms. Harmful ultraviolet light can come from
both sun light and from artificial light sources. The risk from
exposure to ultraviolet light from natural sun light is increasing
in portions of the world due to occasional significant drops in the
UV-absorbing ozone layer. Cost effective ways of reducing human
exposure to harmful ultraviolet light are desirable.
[0004] On the other hand, some commercial processes use UV light as
a processing tool. In order to make effective use of UV light in
the processing of microscopic components, precise control of the
light absorption is advantageous. In addition, photocatalytic
materials can catalyze chemical reactions upon exposure to
appropriate light. Efficient approaches for utilization of these
commercial processes can greatly expand their commercial scope.
SUMMARY OF THE INVENTION
[0005] Small particles, especially nanoscale particles, are useful
as absorbers of ultraviolet light. Due to their small size,
nanoscale particles can be relatively transparent to visible light.
Similarly, the UV absorption spectrum depends on the particle
diameters. Laser pyrolysis provides a important source of UV
absorbing, nanoscale particles with relatively narrow distributions
of diameters. The particles are useful for producing UV blocking
materials. The particles are also very useful for producing sharp
boundaries for electrical components on electronic circuit boards
produced using photoresist. Also, the UV absorbing particles can be
used as photocatalysts that create an oxidizing potential upon
illumination with UV light.
[0006] In a first aspect, the invention features a light bulb
including a light source and a screen substantially transparent to
visible light, the screen comprising metal oxide particles having
an average diameter less than about 100 nm. The screen can further
include a silicon glass or an organic polymer. The light source can
include an incandescent filament, a fluorescent light or a halogen
light. The particles preferably have an average diameter from about
5 nm to about 50 nm. The metal oxide particles can include titanium
dioxide, zinc oxide, zinc dioxide or cerium dioxide.
[0007] In another aspect, the invention features a topical ointment
including an ointment vehicle and crystalline particles comprising
metal oxide, the particles having an average diameter of less than
about 100 nm and a diameter distribution such that at least about
95 percent of the particles have a diameter greater than about 60
percent of the average diameter and less than about 140 percent of
the average diameter. The crystalline particles preferably have an
average diameter from about 5 nm to about 50 nm.
[0008] In another aspect, the invention features a window including
a substantially transparent substrate and particles comprising
metal oxide, the particle having an average diameter of less than
about 100 nm. The particles preferably have an average diameter
from about 5 nm to about 50 nm.
[0009] In another aspect, the invention features a photoresist
composition including a photoactivated composition and particles
comprising metal oxide, the particles having an average diameter
from about 5 nm to about 150 nm.
[0010] In another aspect, the invention features a method of
producing a UV absorbing layer comprising the step of applying a
layer of particles to a substantially transparent substrate at low
temperature, the particles comprising metal oxide and having an
average particle diameter from about 5 nm to about 100 nm.
[0011] In another aspect, the invention features an article
comprising a self cleaning surface including discrete particles
that are photocatalytic upon exposure to UV light, said particles
having an average diameter from about 5 nm to about 150 nm. The
self cleaning surface can be mobile. The particles can comprise
TiO.sub.2. The particles can have a diameter distribution such that
at least about 95 percent of the particles have a diameter greater
than about 60 percent of the average diameter and less than about
140 percent of the average diameter.
[0012] In another aspect, the invention features a method of
purifying a fluid comprising the step of contacting the fluid with
a surface comprising discrete particles that are photocatalytic
upon exposure to UV light, the particles having an average diameter
from about 5 nm to about 150 nm, where the surface is exposed to UV
light.
[0013] In another aspect, the invention features a method of
cleaning a hard surface comprising the step of exposing a hard
surface to UV light, the hard surface comprising discrete particles
that are photocatalytic upon exposure to UV light, said particles
having an average diameter from about 5 nm to about 150 nm.
[0014] In another aspect, the invention features a method of
producing titanium oxide particles comprising the step of
pyrolyzing a molecular stream comprising a titanium precursor, an
oxidizing agent and a radiation absorbing gas in a reaction
chamber, where the pyrolysis is driven by heat absorbed from a
laser beam. The laser beam preferably includes infrared light, can
be generated by a CO.sub.2 laser. The oxidizing agent can be
O.sub.2, O.sub.3, CO or CO.sub.2. In a preferred embodiment, the
molecular stream is generated by a nozzle substantially elongated
in one dimension relative to the orthogonal direction.
[0015] Other features and advantages of the invention are evident
from the detailed description and claims below.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 is a schematic illustration of the effect on surface
area due to a reduction in particle diameter.
[0017] FIG. 2 is a schematic, sectional view of an embodiment of a
laser pyrolysis apparatus taken through the middle of the laser
radiation path. The upper insert is a bottom view of the injection
nozzle, and the lower insert is a top view of the collection
nozzle.
[0018] FIG. 3 is a schematic, perspective view of a reaction
chamber of an alternative embodiment of the laser pyrolysis
apparatus, where the materials of the chamber are depicted as
transparent to reveal the interior of the apparatus.
[0019] FIG. 4 is a sectional view of the reaction chamber of FIG. 2
taken along line 4-4.
[0020] FIG. 5 is a schematic, sectional view of an oven for heating
particles, in which the section is taken through the center of the
quartz tube.
[0021] FIG. 6 is a schematic representation of an ointment of the
invention.
[0022] FIG. 7 is a schematic representation of UV block materials
incorporated into a substrate.
[0023] FIG. 8 is a schematic representation of the incorporation of
the UV block particles into a light source.
[0024] FIG. 9 is a schematic representation of UV absorbing
particles used in combination with photoresist to obtain
higher-definition edges in patterns on a substrate.
[0025] FIG. 10 is a schematic representation of the use of UV
absorbing particles as a mask to pattern photoresist on a
substrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Metal oxide particles with average diameters less than about
1000 nm and especially less than about 100 nm have been found to be
useful components for systems designed to block or to exploit UV
light. Titanium dioxide (TiO.sub.2), zinc oxide (ZnO), zinc dioxide
(ZnO.sub.2) and cerium dioxide (CeO.sub.2) are of particular
interest. Because of the small size of the particles, optical
scattering becomes negligible so that the particles become
generally transparent to visible light. On the other hand, the UV
absorption properties of the particles can be controlled by
appropriate selection of the distribution of particle diameters.
Laser pyrolysis, as described below, is an efficient method for
producing metal oxide particles with a selected average particle
diameter and a narrow distribution of diameters.
[0027] A basic feature of successful application of laser pyrolysis
for the production of nanoscale metal oxide particles is production
of a molecular stream containing a metal precursor compound, a
radiation absorber and an oxygen source. The molecular stream is
pyrolyzed by an intense laser beam. The intense heat resulting from
the absorption of the laser radiation induces the oxidation of the
metal precursor compound in the oxidizing environment. The laser
pyrolysis provides for formation of metal oxides particles that may
be difficult to form under thermodynamic equilibrium conditions. As
the molecular stream leaves the laser beam, the metal oxide
particles are rapidly quenched. The metal oxide particles produced
by laser pyrolysis can be subjected to further processing to alter
and/or improve the properties of the particles.
[0028] The small size of the particles results in a significantly
increased surface area for a given weight of material. The
increased surface area is depicted graphically in FIG. 1., assuming
spherical particles and no aggregation. The increased surface area
of the particles can be directly advantageous for certain
applications such as catalysis. In addition, a large surface area
may enhance the UV absorption cross section for a given quantity of
material.
[0029] A. Particle Production
[0030] Laser pyrolysis has been discovered to be a valuable tool
for the production of nanoscale metal oxide particles of interest.
In addition, the metal oxide particles produced by laser pyrolysis
are a convenient material for further processing to expand the
pathways for the production of desirable metal oxide particles.
Thus, using laser pyrolysis alone or in combination with additional
processes, a wide variety of metal oxide particles can be produced.
In some cases, alternative production pathways can be followed to
produce comparable particles.
[0031] The reaction conditions determine the qualities of the metal
oxide particles produced by laser pyrolysis. The reaction
conditions for laser pyrolysis can be controlled relatively
precisely in order to produce particles with desired properties.
The appropriate reaction conditions to produce a certain type of
particles generally depend on the design of the particular
apparatus. Nevertheless, some general observations can be made on
the relationship between reaction conditions and the resulting
particles.
[0032] Increasing the laser power results in increased reaction
temperatures in the reaction region as well as a faster quenching
rate. A rapid quenching rate tends to favor production of higher
energy structures. Similarly, increasing the chamber pressure also
tends to favor the production of higher energy structures. Also,
increasing the concentration of oxygen source in the reactant
stream favors the production of metal oxides with increased amounts
of oxygen, i.e., higher oxidation states of the metal, for metals
that multiple, stable oxidation states.
[0033] Reactant gas flow rate and velocity of the reactant gas
stream are inversely related to particle size so that increasing
the reactant gas flow rate or velocity tends to result in smaller
particle size. Also, the growth dynamics of the particles have a
significant influence on the size of the resulting particles. In
other words, different crystal forms of metal oxide have a tendency
to form different size particles from other crystal forms under
relatively similar conditions. Laser power also influences particle
size with increased laser power favoring larger particle formation
for lower melting materials and smaller particle formation for
higher melting materials.
[0034] Appropriate precursor compounds generally include metal
compounds with reasonable vapor pressures, i.e., vapor pressures
sufficient to get desired amounts of precursor vapor in the
reactant stream. The vessel holding the precursor compounds can be
heated to increase the vapor pressure of the metal compound
precursor, if desired. Preferred titanium precursors include, for
example, TiCl.sub.4, Ti(CH.sub.3).sub.4 and
Ti[OCH(CH.sub.3).sub.2].sub.4 (titanium tetra-1-propoxide).
Preferred cerium precursors include, for example,
Ce(OC.sub.3H.sub.7).sub.4 (cerium i-propoxide), and
(C.sub.5H.sub.5).sub.3Ce (tris (cyclopentadienyl)cerium- ).
Preferred zinc precursors include, for example, ZnCl.sub.2.
ZnCl.sub.2 vapor can be generated by heating and, optionally,
melting ZnCl.sub.2 solids. For example, ZnCl.sub.2 has a vapor
pressure of about 5 mm Hg at a temperature of about 500.degree. C.
When using ZnCl.sub.2 precursor, the chamber and nozzle preferably
are heated to avoid getting condensation of the precursor.
[0035] Preferred oxygen sources include, for example, O.sub.2, CO,
CO.sub.2, O.sub.3 and mixtures thereof. The oxygen source should
not react significantly with the metal precursor compound prior to
entering the reaction zone since this generally would result in the
formation of large particles.
[0036] Laser pyrolysis can be performed with a variety of optical
laser frequencies. Preferred lasers operate in the infrared portion
of the electromagnetic spectrum. CO.sub.2 lasers are particularly
preferred sources of laser light. Infrared absorbers for inclusion
in the molecular stream include, for example, C.sub.2H.sub.4,
NH.sub.3, SF.sub.6 and O.sub.3. O.sub.3 can act as both an infrared
absorber and as an oxygen source. The radiation absorber, such as
the infrared absorber, absorbs energy from the radiation beam and
distributes the energy as heat to the other reactants to drive the
pyrolysis.
[0037] Preferably, the energy absorbed from the radiation beam
increases the temperature at a tremendous rate, many times the rate
that energy generally would be produced even by strongly exothermic
reactions under controlled condition. While the process generally
involves nonequilibrium conditions, the temperature can be
described approximately based on the energy in the absorbing
region. The laser pyrolysis process is qualitatively different from
the process in a combustion reactor where an energy source
initiates a reaction, but the reaction is driven by energy given
off by an exothermic reaction.
[0038] An inert shielding gas can be used to reduce the amount of
reactant and product molecules contacting the reactant chamber
components. For the production of titanium dioxide, zinc oxides and
cerium dioxide particles, appropriate shielding gases include, for
example, Ar, He and N.sub.2.
[0039] An appropriate laser pyrolysis apparatus generally includes
a reaction chamber isolated from the ambient environment. A
reactant inlet connected to a reactant supply system produces a
molecular stream through the reaction chamber. A laser beam path
intersects the molecular stream at a reaction zone. The molecular
stream continues after the reaction zone to an outlet, where the
molecular stream exits the reaction chamber and passes into a
collection system. Generally, the laser is located external to the
reaction chamber, and the laser beam enters the reaction chamber
through an appropriate window.
[0040] Referring to FIG. 2, a particular embodiment 100 of a
pyrolysis apparatus involves a reactant supply system 102, reaction
chamber 104, collection system 106 and laser 108. Reactant supply
system 102 includes a source 120 of metal precursor compound. For
liquid precursors, a carrier gas from carrier gas source 122 can be
introduced into precursor source 120, containing liquid precursor
to facilitate delivery of the precursor. The carrier gas from
source 122 preferably is either an infrared absorber or an inert
gas and is preferably bubbled through the liquid, metal precursor
compound. The quantity of precursor vapor in the reaction zone is
roughly proportional to the flow rate of the carrier gas.
[0041] Alternatively, carrier gas can be supplied directly from
infrared absorber source 124 or inert gas source 126, as
appropriate. The oxidizing agent is supplied from source 128, which
can be a gas cylinder or other appropriate container. The gases
from the metal precursor compound source 120 are mixed with gases
from oxidizing agent source 128, infrared absorber source 124 and
inert gas source 126 by combining the gases in a single portion of
tubing 130. The gases are combined a sufficient distance from
reaction chamber 104 such that the gases become well mixed prior to
their entrance into reaction chamber 104. The combined gas in tube
130 passes through a duct 132 into rectangular channel 134, which
forms part of an injection nozzle for directing reactants into the
reaction chamber.
[0042] Flow from sources 122, 124, 126 and 128 are preferably
independently controlled by mass flow controllers 136. Mass flow
controllers 136 preferably provide a controlled flow rate from each
respective source. Suitable mass flow controllers include, for
example, Edwards Mass Flow Controller, Model 825 series, from
Edwards High Vacuum International, Wilmington, Mass.
[0043] Inert gas source 138 is connected to an inert gas duct 140,
which flows into annular channel 142. A mass flow controller 144
regulates the flow of inert gas into inert gas duct 140. Inert gas
source 126 can also function as the inert gas source for duct 140,
if desired.
[0044] The reaction chamber 104 includes a main chamber 200.
Reactant supply system 102 connects to the main chamber 200 at
injection nozzle 202. The end of injection nozzle 202 has an
annular opening 204 for the passage of inert shielding gas, and a
rectangular slit 206 for the passage of reactant gases to form a
molecular stream in the reaction chamber. Annular opening 204 has,
for example, a diameter of about 1.5 inches and a width along the
radial direction of about {fraction (1/16)} in. The flow of
shielding gas through annular opening 204 helps to prevent the
spread of the reactant gases and product particles throughout
reaction chamber 104.
[0045] Tubular sections 208, 210 are located on either side of
injection nozzle 202. Tubular sections 208, 210 include ZnSe
windows 212, 214, respectively. Windows 212, 214 are about 1 inch
in diameter. Windows 212, 214 are preferably plane-focusing lenses
with a focal length equal to the distance between the center of the
chamber to the surface of the lens to focus the beam to a point
just below the center of the nozzle opening. Windows 212, 214
preferably have an antireflective coating. Appropriate ZnSe lenses
are available from Janos Technology, Townshend, Vt. Tubular
sections 208, 210 provide for the displacement of windows 212, 214
away from main chamber 200 such that windows 212, 214 are less
likely to be contaminated by reactants or products. Window 212, 214
are displaced, for example, about 3 cm from the edge of the main
chamber 200.
[0046] Windows 212, 214 are sealed with a rubber o-ring to tubular
sections 208, 210 to prevent the flow of ambient air into reaction
chamber 104. Tubular inlets 216, 218 provide for the flow of
shielding gas into tubular sections 208, 210 to reduce the
contamination of windows 212, 214. Tubular inlets 216, 218 are
connected to inert gas source 138 or to a separate inert gas
source. In either case, flow to inlets 216, 218 preferably is
controlled by a mass flow controller 220.
[0047] Laser 108 is aligned to generate a laser beam 222 that
enters window 212 and exits window 214. Windows 212, 214 define a
laser light path through main chamber 200 intersecting the flow of
reactants at reaction zone 224. After exiting window 214, laser
beam 222 strikes power meter 226, which also acts as a beam dump.
An appropriate power meter is available from Coherent Inc., Santa
Clara, Calif. Laser 108 can be replaced with an intense
conventional light source such as an arc lamp. Preferably, laser
108 is an infrared laser, especially a CW CO.sub.2 laser such as an
1800 watt maximum power output laser available from PRC Corp.,
Landing, N.J.
[0048] Reactants passing through slit 206 in injection nozzle 202
initiate a molecular stream. The molecular stream passes through
reaction zone 224, where reaction involving the metal precursor
compound takes place. Heating of the gases in reaction zone 224 is
extremely rapid, roughly on the order of 10.sup.5.degree. C./sec
depending on the specific conditions. The reaction is rapidly
quenched upon leaving reaction zone 224, and nanoparticles 228 are
formed in the molecular stream. The nonequilibrium nature of the
process allows for the production of nanoparticles with a highly
uniform size distribution and structural homogeneity.
[0049] The path of the molecular stream continues to collection
nozzle 230. Collection nozzle 230 is spaced about 2 cm from
injection nozzle 202. The small spacing between injection nozzle
202 and collection nozzle 230 helps reduce the contamination of
reaction chamber 104 with reactants and products. Collection nozzle
230 has a circular opening 232. Circular opening 232 feeds into
collection system 106.
[0050] The chamber pressure is monitored with a pressure gauge
attached to the main chamber. The chamber pressure generally ranges
from about 5 Torr to about 1000 Torr. The preferred chamber
pressure for the production of titanium oxides, zinc oxides and
cerium oxides ranges from about 40 Torr to about 400 Torr.
[0051] Reaction chamber 104 has two additional tubular sections not
shown. One of the additional tubular sections projects into the
plane of the sectional view in FIG. 2, and the second additional
tubular section projects out of the plane of the sectional view in
FIG. 2. When viewed from above, the four tubular sections are
distributed roughly, symmetrically around the center of the
chamber. These additional tubular sections have windows for
observing the inside of the chamber. In this configuration of the
apparatus, the two additional tubular sections are not used to
facilitate production of nanoparticles.
[0052] Collection system 106 can include a curved channel 250
leading from collection nozzle 230. Because of the buoyant nature
of the nanoparticles, the product nanoparticles follow the flow of
the gas around curves. Collection system 106 includes a filter 252
within the gas flow to collect the product nanoparticles. A variety
of materials such as teflon, glass fibers and the like can be used
for the filter as long as the material is inert and has a fine
enough mesh to trap the particles. Preferred materials for the
filter include, for example, a glass fiber filter from ACE Glass
Inc., Vineland, N.J.
[0053] Pump 254 is used to maintain collection system 106 at a
reduced pressure. A variety of different pumps can be used.
Appropriate pumps 254 include, for example, Busch Model B0024 pump
from Busch, Inc., Virginia Beach, Va. with a pumping capacity of
about 25 cubic feet per minute (cfm) and Leybold Model SV300 pump
from Leybold Vacuum Products, Export, Pa. with a pumping capacity
of about 195 cfm. It may be desirable to flow the exhaust of the
pump through a scrubber 256 to remove any remaining reactive
chemicals before venting into the atmosphere. The entire apparatus
100 can be placed in a fume hood for ventilation purposes and for
safety considerations. Generally, the laser remains outside of the
fume hood because of its large size.
[0054] The apparatus is controlled by a computer. Generally, the
computer controls the laser and monitors the pressure in the
reaction chamber. The computer can be used to control the flow of
reactants and/or the shielding gas. The pumping rate is controlled
by either a manual needle valve or an automatic throttle valve
inserted between pump 254 and filter 252. As the chamber pressure
increases due to the accumulation of particles on filter 252, the
manual valve or the throttle valve can be adjusted to maintain the
pumping rate and the corresponding chamber pressure.
[0055] The reaction can be continued until sufficient nanoparticles
are collected on filter 252 such that the pump can no longer
maintain the desired pressure in the reaction chamber 104 against
the resistance through filter 252. When the pressure in reaction
chamber 104 can no longer be maintained at the desired value, the
reaction is stopped, and the filter 252 is removed. With this
embodiment, about 3-75 grams of nanoparticles can be collected in a
single run before the chamber pressure can no longer be maintained.
A single run generally can last from about 10 minutes to about 3
hours depending on the type of particle being produced and the
particular filter. Therefore, it is straightforward to produce a
macroscopic quantity of nanoparticles, i.e., a quantity visible
with the naked eye.
[0056] The reaction conditions can be controlled relatively
precisely. The mass flow controllers are quite accurate. The laser
generally has about 0.5 percent power stability. With either a
manual control or a throttle valve, the chamber pressure can be
controlled to within about 1 percent.
[0057] The configuration of the reactant supply system 102 and the
collection system 106 can be reversed. In this alternative
configuration, the reactants are supplied from the bottom of the
reaction chamber, and the product particles are collected from the
top of the chamber. This alternative configuration tends to result
in a slightly higher collection of product since metal oxide
nanoscale particles generally are buoyant in the surrounding gases.
In this configuration, it is preferable to include a curved section
in the collection system so that the collection filter is not
mounted directly above the reaction chamber.
[0058] An alternative design of a laser pyrolysis apparatus has
been described. See, commonly assigned, copending U.S. patent
application Ser. No. 08/808,850, now U.S. Pat. No. 5,958,348,
entitled "Efficient Production of Particles by Chemical Reaction,"
incorporated herein by reference. This alternative design is
intended to facilitate production of commercial quantities of
nanoparticles. A variety of configurations are described for
injecting the reactant materials into the reaction chamber.
[0059] The alternative apparatus includes a reaction chamber
designed to minimize contamination of the walls of the chamber with
particles, to increase the production capacity and to make
efficient use of resources. To accomplish these objectives, the
reaction chamber conforms generally to the shape of an elongated
reactant inlet, decreasing the dead volume outside of the molecular
stream. Gases can accumulate in the dead volume, increasing the
amount of wasted radiation through scattering or absorption by
nonreacting molecules. Also, due to reduced gas flow in the dead
volume, particles can accumulate in the dead volume causing chamber
contamination.
[0060] The design of the improved reaction chamber 300 is
schematically shown in FIGS. 3 and 4. A reactant gas channel 302 is
located within block 304. Facets 306 of block 304 form a portion of
conduits 308. Another portion of conduits 308 join at edge 310 with
an inner surface of main chamber 312. Conduits 308 terminate at
shielding gas inlets 314. Block 304 can be repositioned or
replaced, depending on the reaction and desired conditions, to vary
the relationship between the elongated reactant inlet 316 and
shielding gas inlets 314. The shielding gases from shielding gas
inlets 314 form blankets around the molecular stream originating
from reactant inlet 316.
[0061] The dimensions of elongated reactant inlet 316 preferably
are designed for high efficiency particle production. Reasonable
dimensions for the reactant inlet for the production of metal oxide
particle, when used with a 1800 watt CO.sub.2 laser, are from about
5 mm to about 1 meter.
[0062] Main chamber 312 conforms generally to the shape of
elongated reactant inlet 316. Main chamber 312 includes an outlet
318 along the molecular stream for removal of particulate products,
any unreacted gases and inert gases. Tubular sections 320, 322
extend from the main chamber 312. Tubular sections 320, 322 hold
windows 324, 326 to define a laser beam path 328 through the
reaction chamber 300. Tubular sections 320, 322 can include
shielding gas inlets 330, 332 for the introduction of shielding gas
into tubular sections 320, 322.
[0063] The improved apparatus includes a collection system to
remove the nanoparticles from the molecular stream. The collection
system can be designed to collect a large quantity of particles
without terminating production or, preferably, to run in continuous
production by switching between different particle collectors
within the collection system. The collection system can include
curved components within the flow path similar to curved portion of
the collection system shown in FIG. 2. The configuration of the
reactant injection components and the collection system can be
reversed such that the particles are collected at the top of the
apparatus.
[0064] As noted above, properties of the metal oxide nanoparticles
can be modified by further processing. For example, the heating
process can be used to increase the uniformity and/or crystallinity
of the particles and possibly to remove adsorbed compounds on the
particles. In addition, the metal oxide particles can be heated in
an oven to alter the oxygen content and/or crystal structure of the
metal oxide. The atmosphere surrounding the particles in the oven
can be an oxidizing environment or an inert environment. It has
been discovered that use of mild conditions, i.e., temperatures
well below the melting point of the nanoparticles, can result in
modification of the stoichiometry or crystal structure of metal
oxides without significantly sintering the nanoparticles into
larger particles. This processing in an oven is further discussed
in commonly assigned, copending U.S. patent application Ser. No.
08/897,903, now U.S. Pat. No. 5,989,514, entitled "Processing of
Vanadium Oxide Particles With Heat," incorporated herein by
reference.
[0065] An example of an apparatus 400 to perform this heat
processing is displayed in FIG. 5. Apparatus 400 includes a tube
402 into which the nanoparticles are placed. Tube 402 is connected
to an oxidizing gas source 404 and inert gas source 406. Oxidizing
gas, inert gas or a combination thereof to produce the desired
atmosphere are placed within tube 402.
[0066] Preferably, the desired gases are flowed through tube 402.
Appropriate active gases to produce an oxidizing environment
(oxidizing gas) include, for example, O.sub.2, O.sub.3, CO,
CO.sub.2 and combinations thereof. The oxidizing gases can be
diluted with inert gases such as Ar, He and N.sub.2. The gases in
tube 402 can be exclusively inert gases, if desired.
[0067] Tube 402 is located within oven or furnace 408. Oven 408
maintains the relevant portions of the tube at a relatively
constant temperature, although the temperature can be varied
systematically through the processing step, if desired. Temperature
in oven 408 generally is measured with a thermocouple 410. The
metal oxide particles can be placed in tube 402 within a vial 412.
Vial 412 prevents loss of the particles due to gas flow. Vial 412
generally is oriented with the open end directed toward the
direction of the source of the gas flow.
[0068] The precise conditions including type of oxidizing gas (if
any), concentration of oxidizing gas, pressure or flow rate of gas,
temperature and processing time can be selected to produce the
desired type of product material. The temperatures generally are
mild, i.e., significantly below the melting point of the material.
The use of mild conditions avoids interparticle sintering resulting
in larger particle sizes. Some controlled sintering of the metal
oxide particles can be performed in oven 408 at somewhat higher
temperatures to produce slightly larger average particle
diameters.
[0069] For the processing of titanium dioxide or zinc oxide, the
temperatures preferably range from about 50.degree. C. to about
1000.degree. C., more preferably from about 50.degree. C. to about
500.degree. C., and even more preferably from about 50.degree. C.
to about 200.degree. C. The nanoparticles preferably are heated for
about 1 hour to about 100 hours. Some empirical adjustment may be
required to produce the conditions appropriate for yielding a
desired material.
[0070] B. Particle Properties
[0071] A collection of preferred metal oxide particles, such as
titanium dioxide, zinc dioxide or cerium dioxide particles, has an
average diameter of less than a micron, preferably from about 5 nm
to about 500 nm and more preferably from about 5 nm to about 100
nm, and even more preferably from about 5 nm to about 50 .mu.m. The
particles generally have a roughly spherical gross appearance. Upon
closer examination, the particles generally have facets
corresponding to the underlying crystal lattice. Nevertheless, the
particles tend to exhibit growth that is roughly equal in the three
physical dimensions to give a gross spherical appearance. Diameter
measurements on particles with asymmetries are based on an average
of length measurements along the principle axes of the particle.
The measurements along the principle axes preferably are each less
than about 1 micron for at least about 95 percent of the
nanoparticles, and more preferably for at least about 98 percent of
the nanoparticles.
[0072] Because of their small size, the particles tend to form
loose agglomerates due to van der Waals forces between nearby
particles. Nevertheless, the nanometer scale of the particles is
clearly observable in transmission electron micrographs of the
particles. For crystalline particles, the particle size generally
corresponds to the crystal size. The particles generally have a
surface area corresponding to particles on a nanometer scale as
observed in the micrographs. Furthermore, the particles manifest
unique properties due to their small size and large surface area
per weight of material.
[0073] One manifestation of the small size of the particles is
their transparency with respect to visible light for particles that
have a diameter smaller than about 50 .mu.m. Particles with a
diameter smaller than about 50 nm are transparent because they do
not significantly scatter or absorb visible light. These particles
also exhibit a modified UV absorption spectrum that reflects the
distribution of particle diameters.
[0074] As produced, the particles preferably have a high degree of
uniformity in size. As determined from examination of transmission
electron micrographs, the particles generally have a distribution
in sizes such that at least about 95 percent of the particles have
a diameter greater than about 40 percent of the average diameter
and less than about 160 percent of the average diameter.
Preferably, the nanoparticles have a distribution of diameters such
that at least about 95 percent of the particles have a diameter
greater than about 60 percent of the average diameter and less than
about 140 percent of the average diameter. The narrow size
distributions can be exploited in a variety of applications, as
described below. For some of the applications, it may be desirable
to mix particles having narrow diameter distributions to produce a
desired distribution of particle diameters.
[0075] In addition, the nanoparticles generally have a very high
purity level. Metal oxide nanoparticles produced by the above
methods are expected to have a purity greater than the reactant
gases because the crystal formation process tends to exclude
contaminants from the lattice. Furthermore, metal oxide particles
produced by laser pyrolysis have been found to have a high degree
of crystallinity.
[0076] Titanium dioxide is known to exist in three crystalline
phases, anatase, rutile and brookite, as well as an amorphous
phase. The anatase and rutile phases have a tetrahedral crystal
lattice, and the brookite phase has an orthorhombic crystal
structure. Although under certain conditions mixed phase material
can be formed, laser pyrolysis generally can be effectively used to
produce single phase crystalline particles. The conditions of the
laser pyrolysis can be varied to favor the formation of a single,
selected phase of TiO.sub.2. In addition, heating of small metal
oxide particles under mild conditions can be used to effectively
alter the phase or composition of the materials.
[0077] Zinc oxides can have a stoichiometry of, at least, ZnO
(hexagonal, Wurtzite structure) or ZnO.sub.2. Cerium oxides are
known with stoichiometries of CeO.sub.2 (cubic, fluorite structure)
and Ce.sub.2O.sub.3 (hexagonal, Lanthanum oxide structure) as well
as nonstiochiometric variations on these materials. Production
parameters can be varied to select for a particular stoichiometry
of zinc oxide and cerium oxide.
[0078] C. UV Block Compositions
[0079] UV block compositions are useful for a variety of
applications. For example, UV block compositions are useful in
ointments for application to prevent personal exposure, as
materials to prevent passage of UV light from a source into a
protected environment and in processing for controlling the path of
UV light. Refering to FIG. 6, topical ointments 430 generally
involve an ointment vehicle 432 and UV absorbing particles 434. The
ointment vehicle can be aqueous based, oil based or solid based. A
variety of ointment vehicles are known in the art, for example, as
described in U.S. Pat. No. 4,842,832, incorporated herein by
reference. The topical ointment can take the form of a sun screen,
a cosmetic, and the like. The UV particles can be selected to block
out a desired portion of the UV spectrum, as described further
below.
[0080] Blocking out UV light from a protected environment can
involve blocking UV light from a natural (i.e., solar) light source
or from artificial light sources. Blocking UV light from natural
light generally involves production of a window that selectively is
transparent for visible light while absorbing UV light. Windows are
any surfaces through which light is transmitted, regardless of
shape or location. The TiO.sub.2, ZnO, ZnO.sub.2 and CeO.sub.2
particles described above are particularly suitable for this
application because of their relative transparency with respect to
visible light.
[0081] The window can be made from an inorganic glass such as a
silicon based glass, an organic polymer such as high density
polyethylene and polyesters, and the like. The particles can be
placed as a coating on the window or the particles can be dispersed
within the window material (FIG. 7). A coating can be applied in a
variety of ways such as spray coating of a solvent dispersion, spin
coating and deposition of a particle stream.
[0082] With respect to artificial light sources, the lights
generally have a substantially transparent enclosure. The particles
described herein can be incorporated into the enclosure to absorb
the UV light without substantially reducing the amount of visible
light from the light source, as depicted in FIG. 8. As shown in
FIG. 8, the enclosure 450 around light source 452 includes a
coating 454 of nanoparticles. The light source can be an
incandescent light, a fluorescent light, a halogen light, or the
any similar light source.
[0083] Photoresist compositions are used in the production of solid
state electronic devices. A particularly important application of
UV block materials in processing involves the incorporation of the
materials into photoresist materials to sharpen transmission edges.
The objective is to achieve a high aspect ratio of a pattern made
by UV-light lithography. The production of ever smaller structures
corresponding to electronic components on a substrate requires
careful demarcation at the edge of photoresist material used to
produce the structures. The current technology uses both
conventional UV light sources and excimer lasers as the UV light
source.
[0084] Referring to FIG. 9, the photoresist material 502 is
generally applied over a surface 504 of a substrate at specific
locations to be patterned. The patterning is performed by
irradiating the surface with UV light through a mask 506 such that
selected portions of the photoresist 502 are illuminated. The
photoresist material 502 is sensitive to UV light so that it can be
processed after exposure to UV light. The surface of the substrate
504 can reflect incident and transmitted light to further blur
edges 506 resulting in a low aspect ratio of the pattern.
[0085] The use of UV absorbing material in the photoresist can
reduce these effects. The UV absorbing particles 508 can be applied
to the substrate 504, as shown in FIG. 9. The particles can be
applied directly to the substrate or as a composition including
particles embedded in a polymer matrix. The particle absorb UV
light to inhibit the reflection of the light from the surface of
the substrate. The preferred UV absorbing particles described
herein can be used effectively to absorb UV light with small
quantities of material to yield very small patterns on the
substrate as a result of a high aspect ratio. Furthermore, the
small size of the particles further provides for the production of
physically sharp edges for the photoresist material. In another
embodiment, the UV absorbing particles 520 are patterned on a layer
of photoresist 522 to form a mask, as shown in FIG. 10. The
photoresist is layered onto a substrate 524 to be patterned.
Alternatively, the UV absorbing particles can be mixed with the
photoresist material.
[0086] Crystalline particles of TiO.sub.2, ZnO, ZnO.sub.2 and
CeO.sub.2 with average diameters less than about 100 nm have
particularly suitable properties for the production of UV block
materials. These materials are substantially transparent to visible
light. Due to quantum effects in particles with diameters below
about 100 nm and especially below about 50 nm, the energy band gap
widens and the UV absorption spectrum become sharper with an
enhanced absorption capability.
[0087] To design appropriate block for a particular light source,
the UV spectrum of the source is first determined. One can then
select the UV absorbing particles to adequately absorb the UV light
from the source. For use in absorbing UV light from natural sun
light or UV components of light from an artificial light source,
preferably a coating of UV absorbing particles preferably absorbs
greater than about 75 percent and more preferably greater than
about 90 percent of the UV light. It may be desirable to
preferentially absorb UV B light, which can be more harmful to
humans.
[0088] D. Photocatalytic Activity
[0089] Under UV light, certain UV absorbing particles such as
TiO.sub.2 and ZnO become strong oxidizing agents. This oxidizing
capability can be exploited by using the particles as
photocatalysts. These properties are especially useful for
environmentally benign purification and clean-up.
[0090] Using particles with a small average diameter and a narrow
diameter distribution, the absorption efficiency of the particles
generally is localized over a narrow frequency range. Then, the
photocatalytic process can be made more efficient by using a UV
source with an emission spectrum designed for efficient absorption
by the particular metal oxide particles. Furthermore, the use of
appropriately small diameter particles results in particles that
are transparent to visible light.
[0091] Generally, the selected particles are placed in the surface
of a substrate. The substrate can be any suitable material.
Generally, the substrate is selected such that the photocatalyst
particles do not react with the substrate. If the substrate is
transparent to visible light, the substrate with the addition of
suitably small particles also is transparent. The substrate surface
then is contacted with the material to be cleaned. For example,
water containing dirt, oil and the like can be placed within a
vessel with a coating of the particles. Upon exposure to UV light,
the water is cleaned by the strong oxidizing power of the
particles. If the substrate is transparent to UV light, the UV
light can be projected toward the particles from either direction.
Air purification can be accomplished in a similar fashion.
[0092] Hard surface cleaning can be accomplished by adapting this
approach. The surface to be cleaned can be appropriately coated
with suitable metal oxide particles. The surface can be stationary
such as a floor or mobile such as a cutting board surface or a
plate. The surface is used until it is ready to be cleaned. Then,
the surface is exposed to UV light to induce photocatalytic
activity. If the surface is mobile, the coated object can be placed
in a cleaning apparatus for exposure to UV light.
[0093] The embodiments described above are intended to be
representative and not limiting. Additional embodiments of the
invention are within the claims. As will be understood by those
skilled in the art, many changes in the methods and apparatus
described above may be made by the skilled practitioner without
departing from the spirit and scope of the invention, which should
be limited only as set forward in the claims which follow.
* * * * *