U.S. patent application number 10/815900 was filed with the patent office on 2005-12-29 for luminescent nanomaterial powders having predetermined morphology and method of making.
This patent application is currently assigned to General Electric Company. Invention is credited to Karavoor, Geetha, Krishna, Kalaga Murali, Loureiro, Sergio Paulo Martins, Manoharan, Mohan, Saraswat, Shweta.
Application Number | 20050285083 10/815900 |
Document ID | / |
Family ID | 34574886 |
Filed Date | 2005-12-29 |
United States Patent
Application |
20050285083 |
Kind Code |
A1 |
Krishna, Kalaga Murali ; et
al. |
December 29, 2005 |
LUMINESCENT NANOMATERIAL POWDERS HAVING PREDETERMINED MORPHOLOGY
AND METHOD OF MAKING
Abstract
A method of making a luminescent nanomaterial having a plurality
of nanoparticles. The luminescent nanomaterial includes at least
one lanthanide group metal phosphate and at least one lanthanide
series dopant, wherein each of the plurality of nanoparticles has a
predetermined morphology. The luminescent nanomaterial has a high
quantum efficiency and a high absorption value. The method yields a
variety of morphologies and sizes of the plurality of
nanoparticles. The particles size of the luminescent material
varies from tens of nanometers to a few hundred of nanometers.
Inventors: |
Krishna, Kalaga Murali;
(Bangalore, IN) ; Manoharan, Mohan; (Niskayuna,
NY) ; Karavoor, Geetha; (Kasaragod, IN) ;
Saraswat, Shweta; (Bangalore, IN) ; Loureiro, Sergio
Paulo Martins; (Saratoga Springs, NY) |
Correspondence
Address: |
GENERAL ELECTRIC COMPANY (PCPI)
C/O FLETCHER YODER
P. O. BOX 692289
HOUSTON
TX
77269-2289
US
|
Assignee: |
General Electric Company
|
Family ID: |
34574886 |
Appl. No.: |
10/815900 |
Filed: |
March 31, 2004 |
Current U.S.
Class: |
252/301.4P ;
423/263 |
Current CPC
Class: |
B82Y 30/00 20130101;
B82Y 20/00 20130101; C09K 11/7777 20130101 |
Class at
Publication: |
252/301.40P ;
423/263 |
International
Class: |
C09K 011/81 |
Claims
1. A luminescent nanomaterial, said luminescent nanomaterial
comprising a plurality of nanoparticles comprising at least one
lanthanide group metal phosphate and at least one lanthanide series
dopant, wherein each of said plurality of nanoparticles has a
predetermined morphology, and wherein said luminescent nanomaterial
has a quantum efficiency in a range from about 80% to about
100%.
2. (canceled)
3. The luminescent nanomaterial according to claim 1, wherein said
luminescent nanomaterial has a quantum efficiency in a range from
about 80% to about 90%.
4. The luminescent nanomaterial according to claim 1, wherein said
luminescent nanomaterial has a quantum efficiency in a range from
about 90% to about 100%.
5. The luminescent nanomaterial according to claim 1, wherein said
luminescent nanomaterial has a quantum efficiency of at least
100%.
6. The luminescent nanomaterial according to claim 1, wherein said
luminescent nanomaterial has an absorption value of at least
80%.
7. The luminescent nanomaterial according to claim 1, wherein said
lanthanide group metal phosphate comprises at least one of
gadolinium phosphate and lanthanum phosphate.
8. The luminescent nanomaterial according to claim 1, wherein said
lanthanide group metal phosphate is one of lanthanum phosphate,
gadolinium phosphate, gadolinium lanthanum phosphate, and
combinations thereof.
9. The luminescent nanomaterial according to claim 1, wherein said
at least one lanthanide series dopant comprises one of cerium,
terbium, or combinations thereof.
10. The luminescent nanomaterial according to claim 1, wherein each
of said plurality of nanoparticles has at least one dimension in a
range from about 5 nm to about 500 nm.
11. The luminescent nanomaterial according to claim 10, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 10 nm to about 200 nm.
12. The luminescent nanomaterial according to claim 10, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 50 nm to about 100 nm.
13. The luminescent nanomaterial according to claim 1, wherein said
predetermined morphology comprises one of a spheroidal morphology,
an elongated platelet morphology, a rod-like morphology, or
combinations thereof.
14. A luminescent nanomaterial, said luminescent nanomaterial
comprising a plurality of nanoparticles comprising at least one
lanthanide group metal phosphate and at least one lanthanide series
dopant, wherein each of said plurality of nanoparticles has a
predetermined morphology, wherein said predetermined morphology
comprises one of a spheroidal morphology, an elongated platelet
morphology, a rod-like morphology, or combinations thereof, wherein
said luminescent nanomaterial has a quantum efficiency in a range
from about 80% to about 100%, wherein said plurality of
nanoparticles is formed by: a) forming a homogenized precursor
solution of at least one lanthanide group metal precursor and at
least one lanthanide series dopant precursor; b) adding a phosphate
source and a fuel to said precursor solution; c) removing water
from said precursor solution to leave a reaction concentrate; and
d) igniting said reaction concentrate to form a powder comprising
said luminescent nanomaterial.
15. (canceled)
16. The luminescent nanomaterial according to claim 14, wherein
said luminescent nanomaterial has a quantum efficiency in a range
from about 80% to about 90%.
17. The luminescent nanomaterial according to claim 14, wherein
said luminescent nanomaterial has a quantum efficiency in a range
from about 90% to about 100%.
18. The luminescent nanomaterial according to claim 14, wherein
said luminescent nanomaterial has a quantum efficiency of at least
100%.
19. The luminescent nanomaterial according to claim 14, wherein
said luminescent nanomaterial has an absorption value of at least
80%.
20. The luminescent nanomaterial according to claim 14, wherein
said lanthanide group metal phosphate comprises at least one of
gadolinium phosphate and lanthanum phosphate.
21. The luminescent nanomaterial according to claim 14, wherein
said lanthanide group metal phosphate is one of lanthanum
phosphate, gadolinium phosphate, gadolinium lanthanum phosphate,
and combinations thereof.
22. The luminescent nanomaterial according to claim 14, wherein
said at least one lanthanide series dopant comprises one of cerium,
terbium, or combinations thereof.
23. The luminescent nanomaterial according to claim 14, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 5 nm to about 500 nm.
24. The luminescent nanomaterial according to 23, wherein each of
said plurality of nanoparticles has at least one dimension in a
range from about 10 nm to about 200 nm.
25. The luminescent nanomaterial according to claim 23, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 50 nm to about 100 nm.
26. (canceled)
27. A luminescent nanomaterial, wherein said luminescent
nanomaterial has a quantum efficiency in a range from about 80% to
about 100%, said luminescent nanomaterial comprising a plurality of
nanoparticles comprising at least one lanthanide group metal
phosphate and at least one lanthanide series dopant, wherein each
of said plurality of nanoparticles has a predetermined morphology,
and wherein said plurality of nanoparticles is formed by: a)
forming a homogenized precursor solution of at least one lanthanide
group metal precursor and at least one lanthanide series dopant
precursor; b) adding a phosphate source and a fuel to said
precursor solution; c) removing water from said precursor solution
to leave a reaction concentrate; and d) igniting said reaction
concentrate to form a powder comprising said luminescent
nanomaterial.
28. The luminescent nanomaterial according to claim 27, wherein
said luminescent nanomaterial has a quantum efficiency in a range
from about 80% to about 90%.
29. The luminescent nanomaterial according to claim 27, wherein
said luminescent nanomaterial has a quantum efficiency in a range
from about 90% to about 100%.
30. The luminescent nanomaterial according to claim 27, wherein
said luminescent nanomaterial has a quantum efficiency of at least
100%.
31. The luminescent nanomaterial according to claim 27, wherein
said luminescent nanomaterial has an absorption value of at least
80%.
32. The luminescent nanomaterial according to claim 27, wherein
said lanthanide group metal phosphate comprises at least one of
gadolinium phosphate and lanthanum phosphate.
33. The luminescent nanomaterial according to claim 27, wherein
said lanthanide group metal phosphate is one of lanthanum
phosphate, gadolinium phosphate, gadolinium lanthanum phosphate,
and combinations thereof.
34. The luminescent nanomaterial according to claim 27, wherein
said at least one lanthanide series dopant comprises one of cerium,
terbium, or combinations thereof.
35. The luminescent nanomaterial according to claim 27, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 5 nm to about 500 nm.
36. The luminescent nanomaterial according to claim 35, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 50 nm to about 100 nm.
37. The luminescent nanomaterial according to claim 35, wherein
each of said plurality of nanoparticles has at least one dimension
in a range from about 50 nm to about 100 nm.
38. (canceled)
39. A method of making a luminescent nanomaterial comprising a
plurality of nanoparticles comprising at least one lanthanide group
metal phosphate and at least one lanthanide series dopant, wherein
said plurality of nanoparticles has a predetermined morphology, the
method comprising the steps of: a) providing at least one
lanthanide group metal precursor and at least one lanthanide series
dopant precursor; b) forming a homogenized precursor solution
comprising said at least one lanthanide group metal precursor and
said at least one lanthanide series dopant precursor; c) adding a
phosphate source and a fuel to said homogenized precursor solution;
d) removing water from said homogenized precursor solution to leave
a reaction concentrate; and e) igniting said reaction concentrate
to form a powder comprising said plurality of nanoparticles.
40. The method according to claim 39, wherein each of said
lanthanide group metal precursor and said lanthanide series dopant
precursor comprises at least one of an oxide, an acetate, and a
carbonate precursor of a lanthanide group metal.
41. The method according to claim 40, wherein the step of forming a
homogenized precursor solution of at least one lanthanide metal
group precursor comprises: a) reacting the at least one lanthanide
metal group precursor and the at least one lanthanide series dopant
precursor with a nitrate source to form a lanthanide nitrate; and
b) dissolving the lanthanide nitrate in water.
42. The method according to claim 41, wherein the nitrate source
comprises at least one of nitric acid and ammonium nitrate.
43. The method according to claim 39, wherein said lanthanide group
metal precursor and said lanthanide series dopant precursor each
comprise a nitrate precursor of a lanthanide group metal.
44. The method according to claim 39, wherein said homogenized
precursor solution is formed by dissolving said at least one
lanthanide group metal precursors and said at least one lanthanide
series dopant precursor in water.
45. The method according to claim 39, wherein said homogenized
precursor solution has a pH in a range from about 0.5 to about
5.
46. The method according to claim 45, wherein said pH is in a range
from about 1 to about 3.5.
47. The method according to claim 39, wherein said phosphate source
comprises at least one of di-ammonium hydrogen phosphate,
phosphoric acid, and boron phosphate.
48. The method according to claim 39, wherein said fuel is a carbon
source.
49. The method according to claim 48, wherein said carbon source is
urea.
50. The method according to claim 48, wherein said carbon source is
glycine.
51. The method according to claim 48, wherein said carbon source is
hydrazine.
52. The method according to claim 41, wherein said fuel and said
lanthanide nitrate are present in said homogenized precursor
solution, in a ratio in a range from about 1:2 to about 2:1.
53. The method according to claim 39, wherein said homogenized
precursor solution is ignited by a microwave oven.
54. The method according to claim 39, wherein said homogenized
precursor solution is ignited by a furnace.
55. The method according to claim 39, wherein said homogenized
precursor solution is ignited by a hot plate, heated to a
predetermined temperature, wherein said predetermined temperature
is in a range from about 200.degree. C. to about 500.degree. C.
56. (canceled)
57. The method according to claim 55, wherein said predetermined
temperature of is in a range from about 200.degree. C. to about
300.degree. C.
58. The method according to claim 39, further comprising the step
of homogenizing said powder.
59. The method according to claim 39, further comprising the step
of homogenizing said powder, wherein the step of homogenizing said
powder comprises at least one of grinding and milling said
powder.
60. The method according to claim 39 further comprising the step of
stabilizing said powder, wherein the step of stabilizing comprises
heating said powder to a predetermined temperature in a controlled
atmosphere for a period of time, wherein said predetermined
temperature is in a range from about 600.degree. C. to about
1200.degree. C.
61. (canceled)
62. The method according to claim 60, wherein said predetermined
temperature is in a range from about 800.degree. C. to about
1000.degree. C.
63. The heat treatment according to claim [59]60, wherein said
controlled atmosphere comprises one of air, nitrogen, hydrogen, or
combinations thereof.
64. The heat treatment according to claim 60, wherein said period
of time is in a range from about 1 hour to 12 hours.
65. The heat treatment according to claim 64, wherein said period
of time is in a range from about 1 hour to 6 hours.
Description
BACKGROUND OF THE INVENTION
[0001] The invention relates to luminescent nanomaterials. More
particularly, the invention relates to luminescent nanomaterials
comprising a plurality of nanoparticles.
[0002] Luminescent materials, also known as phosphors, are used in
lighting applications. Phosphors are responsible for nearly all the
light output from the lamp. The efficiency of the phosphors to
convert incident non-visible radiation into visible light depends
on the size, shape, and morphology of the phosphor particles.
Consequently, efforts have been directed toward producing
luminescent materials with controlled properties.
[0003] Currently, such luminescent materials comprise particles in
the micron size regime. Since their dimension is more than, or of
the same order of magnitude as 1/4 wavelength of the absorbed
incident radiation, emitted radiation, or both, the particles act
as individual scattering centers for such radiation, thereby
reducing the efficiency of the phosphor due to optical losses.
[0004] Various synthesis routes, such as sol-gel, colloidal,
precipitation, combustion synthesis, and solid state methods have
been adopted to produce powders of luminescent materials. To date,
however, none of the methods have yielded luminescent materials
having selected morphologies that provide optimal efficiency and
absorption.
[0005] Available synthesis methods fail to provide a method of
making sub-micron size luminescent materials having tailored
morphology that provides optimal efficiency and absorption.
Therefore, what is needed is a luminescent material having a
particle size and predetermined or `engineered` morphology that
will optimize both the efficiency and absoprtion of the material.
What is also needed is a method of making such a luminescent
material, wherein the method provides a means of controlling the
morphology of the material.
SUMMARY OF THE INVENTION
[0006] The present invention meets these and other needs by
providing luminescent nanomaterials comprising a plurality of
nanoparticles. The luminescent nanomaterial has at least one
lanthanide group metal phosphate and at least one dopant from the
lanthanide series, wherein each of the plurality of nanoparticles
has a predetermined morphology. The luminescent nanomaterial has
high quantum efficiency and high absorption values. The invention
also provides a method of making such nanoparticles. The method
yields a variety of morphologies. The particle size of the
nanoparticles varies from tens of nanometers to a few hundred of
nanometers.
[0007] Accordingly, one aspect of the invention is to provide a
luminescent nanomaterial. The luminescent nanomaterial comprises a
plurality of nanoparticles. The plurality of nanoparticles
comprises at least one lanthanide group metal phosphate and at
least one lanthanide series dopant, wherein each of the plurality
of nanoparticles has a predetermined morphology.
[0008] Another aspect of the invention is to provide a luminescent
nanomaterial comprising a plurality of nanoparticles. The plurality
of nanoparticles comprises at least one lanthanide group metal
phosphate and at least one lanthanide series dopant, wherein each
of the plurality of nanoparticles has a predetermined morphology.
The method comprises the steps of: forming a homogenized precursor
solution of at least one lanthanide group metal precursor and at
least one lanthanide series dopant precursor; adding a phosphate
source and a fuel to the precursor solution; removing water from
the precursor solution to leave a reaction concentrate; and
igniting the reaction concentrate to form a powder comprising the
plurality of nanoparticles.
[0009] Yet another aspect of the invention is a luminescent
nanomaterial comprising a plurality of nanoparticles and having a
quantum efficiency in a range from about 80% to about 100% with an
absorption value of at least 80%. The plurality of nanoparticles
comprises at least one lanthanide group metal phosphate and at
least one lanthanide series dopant, wherein each of the plurality
of nanoparticles has a predetermined morphology. The method
comprises the steps of: forming a homogenized precursor solution of
at least one lanthanide group metal precursor and at least one
lanthanide series dopant precursor; adding a phosphate source and a
fuel to the precursor solution; removing water from the precursor
solution to leave a reaction concentrate; and igniting the reaction
concentrate to form a powder comprising the plurality of
nanoparticles.
[0010] Another aspect of the invention is to provide the method of
making luminescent nanomaterial comprising a plurality of
nanoparticles having at least one lanthanide group metal phosphate
and at least one lanthanide series dopant, wherein said plurality
of nanoparticles has a predetermined morphology. The method
comprises the steps of: forming a homogenized precursor solution of
at least one lanthanide group metal precursor and at least one
lanthanide series dopant precursor; adding a phosphate source and a
fuel to the precursor solution; removing water from the precursor
solution to leave a reaction concentrate; and igniting the reaction
concentrate to form a powder comprising the plurality of
nanoparticles.
[0011] These and other aspects, advantages, and salient features of
the present invention will become apparent from the following
detailed description, the accompanying drawings, and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a transmission electron microscopy (TEM) image of
a lanthanum phosphate doped with cerium and terbium having a
spheroidal morphology;
[0013] FIG. 2 is a TEM image of a lanthanum phosphate doped with
cerium and terbium having an elongated platelet morphology;
[0014] FIG. 3 is a TEM image of a gadolinium lanthanum phosphate
doped with cerium and terbium having a rod-like morphology;
[0015] FIG. 4 is a photoluminescence emission spectrum of a
gadolinium lanthanum phosphate doped with cerium and terbium with
respect to green phosphor standard; and
[0016] FIG. 5 is a flow chart illustrating the method for making a
luminescent nanomaterial.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the following description, like reference characters
designate like or corresponding parts throughout the several views
shown in the figures. It is also understood that terms such as
"top," "bottom," "outward," "inward," and the like are words of
convenience and are not to be construed as limiting terms.
[0018] Referring to the drawings in general, it will be understood
that the illustrations are for the purpose of describing different
embodiments of the invention, and are not intended to limit the
invention thereto. Turning to FIG. 1, a luminescent nanomaterial of
the present invention is shown. FIG. 1 is a transmission electron
microscopy (TEM) image of a lanthanum phosphate doped with cerium
and terbium. The luminescent nanomaterial 100 comprises a plurality
of nanoparticles. Each of the nanoparticles has a spheroidal
morphology 110. The plurality of nanoparticles comprises at least
one lanthanide group metal phosphate and at least one lanthanum
series dopant. The luminescent nanomaterial 100 comprises at least
one of a spheroidal morphology 110, an elongated platelet
morphology 120, and a rod-like morphology 130. Each of the
plurality of nanoparticles has at least one of the three dimension
in a range from about 5 nm to about 500 nm. In one embodiment, each
of the plurality of nanoparticles has at least one dimension in a
range from about 10 nm to about 200 nm. In a preferred embodiment,
each of the plurality of nanoparticles has at least one dimension
in a range from about 50 nm to about 100 nm. FIG. 2 is a TEM image
of lanthanum phosphate doped with cerium and terbium nanoparticles
having an elongated platelet morphology 120. FIG. 3 is a TEM image
of gadolinium lanthanum phosphate doped with cerium and terbium
nanoparticles having a rod-like morphology 130.
[0019] To exhibit good photoluminescent properties, luminescent
nanomaterial 100 should have a high quantum efficiency. The quantum
efficiency of the luminescent nanomaterial 100 is measured against
a green phosphor standard (commercially available from Nichia: NP
220-13-70). The green phosphor standard has an average particle
size of about 4 microns. The luminescent nanomaterial 100 and the
green phosphor standard are excited using 254 nm ultraviolet
radiation and the emission is measured for a peak at about 544 nm.
The quantum efficiency of the green phosphor standard is assumed to
be 100%. Hence, a material having an absolute quantum efficiency
equal to that of the green phosphor standard will have a 100%
quantum efficiency according to this convention. Absorption values
of the luminescent nanomaterial 100 and the green phosphor standard
were calculated by measuring the spectral reflectance in the range
of 240 nm to 270 nm against a BaSO.sub.4 standard. FIG. 4 shows a
photoluminescence emission spectrum 140 of gadolinium lanthanum
phosphate doped with cerium and terbium with respect to the
photoluminescence spectrum 150 of the green phosphor standard. The
luminescent nanomaterial 100 has a quantum efficiency in the range
from about 80% to about 100% with an absorption value of at least
80%. In one embodiment, the luminescent nanomaterial 100 has a
quantum efficiency in a range from about 80% to about 90% with
absorption value of at least 80%. In another embodiment, the
luminescent nanomaterial 100 has a quantum efficiency in a range
from about 90% to about 100% with an absorption value of at least
80%. In yet another embodiment, the luminescent nanomaterial has a
quantum efficiency of at least 100% with an absorption value of at
least 80%.
[0020] As previously described herein, particles having a dimension
that is greater than or of the same order of magnitude as 1/4
wavelength of the absorbed radiation, the emitted radiation, or
both act as individual scattering centers for such radiation. Such
scattering leads to optical losses. The luminescent nanomaterials
100 of the present invention comprise a plurality of nanoparticles
that are smaller than the 1/4 wavelength of both the incident and
emitted radiation. Therefore, the nanoparticles do not act as
scattering centers for radiation. Consequently, the luminescent
materials provided by the present invention exhibit reduced optical
losses and are more efficient in lighting applications.
[0021] The luminescent nanomaterial 100 comprises at least one
lanthanide group metal phosphate which acts as a host lattice,
i.e., the basic matrix is formed by the at least one lanthanide
group metal phosphate. In one embodiment, the lanthanide group
metal phosphate comprises at least one of gadolinium phosphate,
lanthanum phosphate, gadolinium lanthanum phosphate, and
combinations thereof. In this particular embodiment, at least one
of lanthanum and gadolinium phosphate forms a host lattice; i.e.,
the basic matrix is at least one of lanthanum phosphate and
gadolinium phosphate, and another lanthanide ion substitutes into
the host lattice. In this particular embodiment, the mole percent
of the lanthanide group metal phosphate acting as the host lattice
is in a range from about 35 mole percent to about 95 mole percent,
and the mole percent of the other lanthanide group metal phosphate
that substitutes into the host lattice is in a range from about 0
mole percent to about 30 mole percent. In a particular embodiment,
the mole percent of gadolinium substituent in the lanthanum
phosphate host lattice is in a range from about 0 mole percent to
about 30 mole percent and the mole percent of lanthanum is in a
range from about 35 mole percent to about 95 mole percent. In a
preferred embodiment, the mole percent of gadolinium in the
lanthanum phosphate host lattice is up to about 30 mole percent and
the lanthanum mole percent is in a range from about 35 mole percent
to about 60 mole percent. In another embodiment, the lanthanum mole
percent in the gadolinium phosphate host lattice is up to about 30
mole percent and the gadolinium mole percent is in a range from
about 35 mole percent to about 95 mole percent. In a preferred
embodiment, the mole percent of lanthanum substituent in the
gadolinium phosphate host lattice is up to about 30 mole percent
and the mole percent of gadolinium is in a range from about 35 mole
percent to about 60 mole percent.
[0022] The host lattice typically contains at least one luminescent
center, also referred to as an activator ion. Exciting radiation is
absorbed by the activator ion. The activator ion is raised to an
excited state, and then returns to ground state by emitting
radiation. An additional ion, referred to as a sensitizer, can be
added to the host lattice to absorb the exciting radiation and
transfer it to the activator ion. The luminescent nanomaterial 100
comprises at least one lanthanide series dopant which acts either
as a sensitizer, an activator ion, or both. In one embodiment, the
lanthanide series dopant comprises cerium, which acts as a
sensitizer, and terbium, which acts as an activator ion. In this
particular embodiment, each lanthanide series dopant is present in
a range from about 1 mole percent to about 30 mole percent in the
host lattice. In a preferred embodiment, cerium and terbium are
each present in a range from about 4 mole percent to about 30 mole
percent.
[0023] Another aspect of the present invention is to provide a
method for synthesis of luminescent nanomaterial 100 comprising a
plurality of nanoparticles. The luminescent nanomaterial 100
comprises at least one lanthanide group metal phosphate and at
least one lanthanide series dopant, wherein each of the plurality
of nanoparticles has a predetermined morphology as described
hereinabove. The method of making luminescent material 100 is
represented in FIG. 5 as a flow chart. The method of making the
luminescent material 100 is based on the principles of combustion
synthesis. Combustion synthesis is a useful, cost effective
technique for materials synthesis and processing. A further
advantage of this method is that it reduces the need for a hydrogen
reduction step to stabilize the lanthanum series dopants in the
preferred valence state for luminescence. Unlike previously known
methods, method 160 described herein provides a process control
over the properties of the synthesized product.
[0024] The method summarized in FIG. 5 begins with step 170, in
which stoichiometric amounts of at least one lanthanide group metal
precursor and at least one lathanide series dopant precursor are
provided. Non-limiting examples of lanthanide group metal
precursors and lanthanide series dopant precursors include, but are
not limited to, oxides, nitrates, acetates, and carbonates of
lanthanide group metals. The oxide, carbonate, and acetate
precursors of lanthanide group metals and lanthanide series dopants
are hereinafter referred to as "non-nitrate precursors".
[0025] The exact methodology adopted in the method depends on the
chemical species that are used as precursors. For example, nitrate
and non-nitrate precursors of the lanthanide group metal are
separated in step 180 so as to allow further processing, depending
on the precursor type.
[0026] Following separation, a non-nitrate precursor, when used is
reacted with a nitrate source, such as, but not limited to, nitric
acid and ammonium nitrate in step 190. As a result of this
exothermic reaction, the non-nitrate precursor is converted to a
lanthanide nitrate.
[0027] In step 200, the nitrate precursor of the lanthanum group
metal and the converted lanthanide nitrate from step 190 are
dissolved in water to form an aqueous solution, which is then
homogenized by stirring. Further, the pH of the solution is
maintained by controlling the ratio of water and nitric acid. In
one embodiment, the pH of the homogenized precursor solution is
maintained in a range from about 0.5 to about 5. In a preferred
embodiment, the pH of the homogenized precursor solution is
maintained in a range from about 1 to about 3.5.
[0028] In step 210, a phosphate source is added to the homogenized
precursor solution of step 200 to form the lanthanide group metal
phosphate. Non-limiting examples of the phosphate source include
di-ammonium hydrogen phosphate, phosphoric acid, and boron
phosphate. Depending on the pH, the homogenized precursor solution
is either clear, translucent, or milky. A relationship between the
morphology of the luminescent nanomaterial 100 and the pH of the
homogenized precursor solution is observed. A spheroidal morphology
110 is achieved for pH values of less than 1.0. A combination of a
spheroidal morphology 110 and an elongated platelet morphology 120
is obtained for pH values in a range from about 1.0 to about 2.5.
An elongated platelet morphology 120 is observed for pH values in a
range from about 2.5 to about 3.5. In addition, fuel is added to
the homogenized precursor solution to provide the source for
ignition of the homogenized precursor solution. Non-limiting
examples of fuel include glycine, urea, and hydrazine.
[0029] In step 220, water is removed from the homogeneous precursor
solution formed in step 210. In one embodiment, the homogeneous
precursor solution is heated by placing at a hot plate that is
maintained at a temperature in a range from about 200.degree. C. to
about 500.degree. C. In a preferred embodiment, the temperature of
the hot plate is in a range from about 200.degree. C. to about
300.degree. C. Alternatively, the homogeneous precursor solution
may be heated in a furnace or a microwave oven. The heating of the
homogeneous precursor solution is followed by boiling, in step 230,
to remove water, leaving behind a reaction concentrate comprising a
slurry or paste containing reaction product. In step 240, further
heating the reaction concentrate leads to foaming of the reaction
concentrate. Foaming of the reaction concentrate is accompanied by
evolution of gases formed as a result of conversion of nitrates to
phosphates. In step 250, foaming is followed by ignition. In one
embodiment, the foaming product ignites and flames to produce a
voluminous, fluffy powder comprising the plurality of
nanoparticles. In another embodiment, foaming is followed by
smoldering of the reaction concentrate, no flame is observed in
this case, although the foaming product turns red hot and smokes.
Yellow smoke is observed when urea is used as a fuel, whereas
black/brown smoke is observed when glycine is used as a fuel.
[0030] In step 260, a powder comprising the luminescent material
100 is obtained as a result of the exothermic reactions described
above. It is typical for the process to progress from step 220 to
step 260 in about 15 minutes.
[0031] After completion of the exothermic reaction, the powder
comprising the plurality of nanoparticles is homogenized (not shown
in FIG. 5). Homogenization of the powder is completed by means
known in the art, such as grinding, milling, and the like.
[0032] The size of each of the plurality of nanoparticles obtained
by method 160 depends on the flame temperature, which in turn is
effected by the fuel-to-oxidizer ratio. The fuel-to-oxidizer ratio
may be varied from about 2:1 to about 1:2. The nitrate precursors
of the lanthanide group metal act as the oxidizer. In the case
where an insufficient amount of oxidizer is present in the
homogeneous precursor solution, oxidizers, such as, but not limited
to, ammonium nitrate, are added to the solution.
[0033] In one embodiment, the powder comprising the plurality of
nanoparticles is stabilized. Stabilization includes crystal growth
and removing any residual carbon from the powder. Stabilization of
the powder is achieved by heating the powder to a predetermined
temperature in a controlled atmosphere for a period of time. In one
embodiment, the predetermined temperature is in a range from about
600.degree. C. to about 1200.degree. C. In a preferred embodiment,
the predetermined temperature is in a range from about 800.degree.
C. to about 1000.degree. C. In one embodiment, the period of heat
treatment of the powder is in a range from about 1 hour to about 12
hours. In a preferred embodiment, the period of heat treatment of
the powder is in a range from about 1 hour to about 6 hours. In one
embodiment, the controlled atmosphere comprises, air, nitrogen,
hydrogen, combinations thereof, and the like.
[0034] The following example illustrates the features of the
invention, and is not intended to limit the invention in any
way.
EXAMPLE 1
[0035] Luminescent nanomaterial 100 was prepared using the
following steps: forming a homogenized precursor solution of at
least one lanthanide group metal precursor and at least one
lanthanide series dopant precursor; adding a phosphate source and a
fuel to the precursor solution; removing water from the precursor
solution to leave a reaction concentrate; and igniting the reaction
concentrate to form a powder comprising the plurality of
nanoparticles.
[0036] A 10 g batch of the composition of gadolinium lanthanum
phosphate doped with cerium and terbium having 37 mole percent
lanthanum, 20 mole percent gadolinium, 28 mole percent cerium, and
15 mole percent terbium was prepared. A precursor solution was
prepared by dissloving hexahydrate lanthanum nitrate (6.65 g),
hexahydrate gadolinium nitrate (3.75 g), hexahydrate cerium nitrate
(5.05 g), and pentahydrate terbium nitrate (2.71 g) in 20 ml of
water. The precursor solution was then homogenized by stirring. The
pH of the precursor solution was adjusted to 0.5 by addition of
water and nitric acid. Final volume of the precursor solution was
100 ml. Di-ammonium hydrogen phosphate (5.48 g) was mixed with the
homogenized precursor solution, and glycine (6.23 g) was added to
the solution. The solution was placed on a pre-heated hot plate and
heated to a temperature of about 300.degree. C. On heating, water
was removed and a reaction concentrate was formed. Upon further
heating, foaming of the reaction concentrate took place. With
continuous heating, the foaming product was ignited and flamed to
produce a voluminous and fluffy powder comprising the plurality of
nanoparticles. The powder was then ground to make it homogeneous.
The homogenized powder was then placed in an alumina crucible and
heated at 1000.degree. C. for 6 hours in a controlled atmosphere
comprising of 1% hydrogen diluted with nitrogen. Flow rates of the
hydrogen/nitrogen mixture was maintained at about 0.5 litres/hour.
Following the heat treatment, X-ray diffraction was carried out to
calculate the particle size of the powder. The mean particle size
was 38 nm. Absorption and quantum efficiency of the powder were
measured using a photoluminescence spectrometer. The quantum
efficiency and absorption values of the so formed luminescent
nanomaterial were found to be 92% and 82%. Spheroidal morphology
110 of the so formed powder was confirmed using TEM.
[0037] The luminescent nanomaterial 100 described hereinabove can
be used in applications such as, display devices, fluorescent
lamps, compact fluorescent lamps, linear fluorescent lamps, light
emitting diodes, imaging applications, and pigment.
[0038] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
* * * * *