U.S. patent application number 17/656844 was filed with the patent office on 2022-07-14 for formation and modifications of ceramic nanowires and their use in functional materials.
The applicant listed for this patent is GEORGIA TECH RESEARCH CORPORATION, Sila Nanotechnologies Inc.. Invention is credited to James BENSON, Eugene BERDICHEVSKY, Danni LEI, Gleb YUSHIN.
Application Number | 20220223312 17/656844 |
Document ID | / |
Family ID | |
Filed Date | 2022-07-14 |
United States Patent
Application |
20220223312 |
Kind Code |
A1 |
YUSHIN; Gleb ; et
al. |
July 14, 2022 |
FORMATION AND MODIFICATIONS OF CERAMIC NANOWIRES AND THEIR USE IN
FUNCTIONAL MATERIALS
Abstract
A catalyst-free synthesis method for the formation of a
metalorganic compound comprising a desired (first) metal may
include, for example, selecting another (second) metal and an
organic solvent, with the second metal being selected to (i) be
more reactive with respect to the organic solvent than the first
metal and (ii) form, upon exposure of the second metal to the
organic solvent, a reaction by-product that is more soluble in the
organic solvent than the metalorganic compound. An alloy comprising
the first metal and the second metal may be first produced (e.g.,
formed or otherwise obtained) and then treated with the organic
solvent in a liquid phase or a vapor phase to form a mixture
comprising (i) the reaction by-product comprising the second metal
and (ii) the metalorganic compound comprising the first metal. The
metalorganic compound may then be separated from the mixture in the
form of a solid.
Inventors: |
YUSHIN; Gleb; (Atlanta,
GA) ; BENSON; James; (Atlanta, GA) ; LEI;
Danni; (Atlanta, GA) ; BERDICHEVSKY; Eugene;
(Alameda, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sila Nanotechnologies Inc.
GEORGIA TECH RESEARCH CORPORATION |
Alameda
ATLANTA |
CA
GA |
US
US |
|
|
Appl. No.: |
17/656844 |
Filed: |
March 28, 2022 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
16005400 |
Jun 11, 2018 |
11328832 |
|
|
17656844 |
|
|
|
|
15395930 |
Dec 30, 2016 |
9994715 |
|
|
16005400 |
|
|
|
|
62307864 |
Mar 14, 2016 |
|
|
|
62295989 |
Feb 16, 2016 |
|
|
|
International
Class: |
H01B 1/02 20060101
H01B001/02; C01F 5/06 20060101 C01F005/06; C01B 13/18 20060101
C01B013/18; C04B 35/622 20060101 C04B035/622; C04B 35/628 20060101
C04B035/628; C01F 7/30 20060101 C01F007/30; C07F 5/06 20060101
C07F005/06; C09C 1/40 20060101 C09C001/40; C09D 1/00 20060101
C09D001/00; C23C 16/455 20060101 C23C016/455 |
Goverment Interests
GOVERNMENT LICENSE RIGHTS
[0002] This invention was made with government support under Award
ID DMR0954925 awarded by the National Science Foundation (NSF). The
government has certain rights in the invention.
Claims
1. A device, comprising: a material structure comprising one or
more elongated particles included therein, the one or more one
dimensional (1D) elongated particles each comprising at least one
metal and each exhibiting a diameter in the range of about 2 nm to
about 10 microns, a length in the range of about 50 nm to about 50
mm, and a corresponding diameter-to-length aspect ratio in the
range of about 1:4 to about 1:10,000,000, wherein the one or more
1D elongated particles each comprise one or more pores.
2. The device of claim 1, wherein the one or more pores comprise
one or more closed internal pores.
3. The device of claim 1, wherein the one or more one 1D elongated
particles comprise one or more 1D ceramic elongated particles.
4. The device of claim 1, wherein at least one of the one or more
pores is filled with a filler material.
5. The device of claim 1, wherein a microstructure of the one or
more 1D elongated particles is amorphous, nanocrystalline or a
combination thereof.
6. The device of claim 1, wherein an average diameter of the one or
more 1D elongated particles is below around 1 micron.
7. The device of claim 1, wherein electrical separation of the
material structure is tuned or reinforced by the one or more 1D
elongated particles.
8. The device of claim 7, wherein the device is an electrochemical
energy storage device, and wherein the material structure is a
separator between an anode and a cathode of the electrochemical
energy storage device.
9. The device of claim 1, wherein electrical generation of the
material structure is tuned or reinforced by the one or more 1D
elongated particles.
10. The device of claim 9, wherein the device is a solar cell.
11. The device of claim 1, wherein light generation of the material
structure is tuned or reinforced by the one or more 1D elongated
particles.
12. The device of claim 11, wherein the device is a light emitting
diode (LED).
13. The device of claim 1, wherein mechanical reinforcement or
scratch resistance of the material structure is tuned or reinforced
by the one or more 1D elongated particles.
14. The device of claim 13, wherein the material structure
comprises a transparent inorganic glass, a transparent polymer, a
biocompatible material, a metal, a membrane, or any combination
thereof.
15. The device of claim 1, wherein a manner in which light is
affected by the material structure is tuned or reinforced by the
one or more 1D elongated particles.
16. The device of claim 15, wherein the material structure further
comprises a transparent inorganic glass or a transparent polymer or
a metal, and wherein the device comprises transparent armor, a
lens, a window, a bulb, jewelry, a watch, glasses, a mirror, a
fiber-optic cable, a screen, a windshield, a display, or any
combination thereof.
17. The device of claim 15, wherein the material structure further
comprises a color additive.
18. The device of claim 1, wherein the at least one metal includes
a metal selected from the group consisting of Ti, Cr, Fe, Co, Ni,
Cu, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Ta, W, Re, Os, Ir, Pt, Al, Zn, Cd,
In, Sn, Sb, Bi, P, La, Ce, Ca, Mg, Sr, and Be.
19. The device of claim 1, wherein the one or more elongated
particles comprise a metal oxide or fluoride or oxy-fluoride or
nitride or oxy-nitride or any combination thereof.
20. The device of claim 19, wherein the metal oxide comprises a
surface on which a coating layer is deposited, or wherein the metal
oxide comprises a surface on which a precursor of the coating layer
is deposited.
21. The device of claim 20, wherein the coating layer is a metal, a
polymer, or a ceramic material.
22. The device of claim 19, wherein the one or more elongated
particles are part of a porous oxide membrane or body.
23. The device of claim 22, wherein the porous oxide membrane or
body is infiltrated with a filler material.
24. The device of claim 23, wherein the filler material comprises a
metal.
25. The device of claim 23, wherein the filler material comprises a
glass.
26. The device of claim 23, wherein the filler material comprises a
polymer.
27. The device of claim 22, wherein the porous oxide membrane or
body comprises a surface on which a polymer layer is deposited.
28. The device of claim 27, wherein the polymer layer closes at
least one pore of the porous oxide membrane or body to prevent ion
transport at temperatures above a threshold temperature in the
range of about 70.degree. C. to about 130.degree. C.
29. The device of claim 1, wherein the one or more elongated
particles comprise two or more elongated particles that are at
least partially bonded to each other.
30. The device of claim 1, wherein the one or more elongated
particles comprise a membrane or body.
Description
CLAIM OF PRIORITY UNDER 35 U.S.C. .sctn. 119
[0001] The present application for patent is a Continuation of U.S.
patent application Ser. No. 16/005,400 entitled "Formation and
Modifications of Ceramic Nanowires and Their Use in Functional
Materials" filed Jun. 11, 2018, which is a Continuation of U.S.
patent application Ser. No. 15/395,930 entitled "Formation and
Modifications of Ceramic Nanowires and Their Use in Functional
Materials" filed Dec. 30, 2016, which claims the benefit of U.S.
Provisional Application No. 62/307,864, entitled "Formation and
Modifications of Ceramic Nanowires and their use in Functional
Materials," filed Mar. 14, 2016, and U.S. Provisional Application
No. 62/295,989, entitled "Low Cost, Aluminum Oxide Nanowires for a
Safer, Higher Power, and Energy Dense All-Ceramic Li-Ion Battery
Separator," filed Feb. 16, 2016, each of which is expressly
incorporated herein by reference in its entirety.
BACKGROUND
Field
[0003] The present disclosure relates generally to the synthesis
and fabrication of nanomaterials and nanocomposites, and more
particularly to the synthesis of nanowires, whiskers, elongated
nanomaterials, porous elongated nanomaterials, and the like, and
their use in polymer, ceramic, glass, and metal composites, as well
as in catalysts, energy storage devices, membranes/separators,
filters, optical devices, and other applications.
Background
[0004] Owing in part to their relatively light weight, high surface
area, and good mechanical properties, elongated ceramic materials
with a diameter less than around 10 microns down to a few
nanometers, a length from around 10 nm to around 1 mm, an aspect
ratio from around 4 to around 20,000, and specific surface area in
the range from around 2 to around 3,000 m.sup.2/g may be utilized
in a broad range of composites and nanocomposites for enhancement
of various mechanical properties, optical properties, thermal
stabilities, and other properties. The production of such
materials, often called ceramic nanowires, nanofibers, or whiskers
(depending on their dimensions and morphology), with controlled
dimensions and at a low cost would be desirable for a wide range of
composite applications as reinforcement. Thermally stable nanowires
and whiskers may be particularly attractive in high temperature
applications. In contrast to carbon nanotubes and carbon
(nano)fibers (other types of elongated nanomaterials made primarily
of carbon atoms), ceramic nanowires may offer improved dispersion,
optical transparency, stability against oxidation at elevated
temperatures, electrical insulation, more easily modifiable
surfaces, and other properties, which make them attractive for
various applications.
[0005] However, despite the useful properties and the commercial
potential of ceramic nanowires, nanofibers, and whiskers, their
applications have been rather limited due to the high cost of the
conventionally-employed synthesis techniques (such as chemical
vapor deposition, hydrothermal synthesis, and others) and the
limited experimental ability to tune their characteristic
dimensions, surface morphology, and other properties.
[0006] Accordingly, there remains a need for improved methods for
synthesis of ceramic nanowires, nanofibers, whiskers, and other
related materials, as well as their modification and use in
composites. There additionally remains a need for improved
materials and improved manufacturing processes.
SUMMARY
[0007] Embodiments disclosed herein address the above stated needs
by providing improved methods of synthesis of nanowires, whiskers,
elongated nanomaterials, porous elongated nanomaterials, and the
like.
[0008] Embodiments disclosed herein also address various
applications of nanowires, whiskers, elongated nanomaterials,
porous elongated nanomaterials, and the like, including those for
improved battery components, improved batteries made therefrom, and
methods of making and using the same.
[0009] As an example, a catalyst-free synthesis method is provided
for the formation of a metalorganic compound comprising a desired
(first) metal. The method may include, for example, selecting
another (second) metal and an organic solvent, with the second
metal being selected to (i) be more reactive with respect to the
organic solvent than the first metal and (ii) form, upon exposure
of the second metal to the organic solvent, a reaction by-product
comprising the second metal that is more soluble in the organic
solvent than the metalorganic compound comprising the first metal.
An alloy comprising the first metal and the second metal may be
first produced (e.g., formed or otherwise obtained) and then
treated with the organic solvent in a liquid phase or a vapor phase
to form a mixture comprising (i) the reaction by-product comprising
the second metal and (ii) the metalorganic compound comprising the
first metal. The metalorganic compound may then be separated from
the mixture in the form of a solid, as described in more detail
below.
[0010] In some designs, the second metal may have a reactivity with
respect to the organic solvent that is at least five times higher
than that of the first metal. Example elements for the first metal
include Ti, Cr, Fe, Co, Ni, Cu, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Ta, W,
Re, Os, Ir, Pt, Al, Zn, Cd, In, Sn, Sb, Bi, P, La, Ce, Ca, Mg, Sr,
and Be. Example elements for the second metal include Li, K, Ca,
and Na.
[0011] When the organic solvent is in the form of a liquid, the
treating may be performed at a temperature in the range of about
-20.degree. C. to about +200.degree. C., for example.
[0012] In some designs, the metalorganic compound may comprise
porous particles. In addition or as an alternative, the
metalorganic compound may comprise elongated particles. The
elongated particles may exhibit, for example, a width in the range
of about 2 nm to about 10 microns, a length in the range of about
50 nm to about 50 mm, and a corresponding width-to-length aspect
ratio in the range of about 1:4 to about 1:10,000,000. 9. Example
metalorganic compounds include various alkoxides.
[0013] For some applications, the method may further comprise
converting the metalorganic compound to a metal oxide compound in
the form of elongated particles. The elongated metal oxide
particles may be porous. The converting may be performed at a
temperature in the range of about -20.degree. C. to about
+1500.degree. C. in an oxygen-containing environment.
[0014] In some designs, a coating layer may be deposited on a
surface of the elongated metal oxide particles or a precursor
thereof. The coating layer may be a metal, a polymer, or a ceramic
material, for example. The coating layer may be deposited via
chemical vapor deposition or atomic vapor deposition.
[0015] For some applications, elongated particles of the
metalorganic compound may be formed into a membrane or body and
converted into elongated metal oxide compound particles to form a
porous oxide membrane or body. The converting may partially bond at
least some of the elongated metal oxide compound particles to each
other. For some applications, the porous oxide membrane or body may
be infiltrated with a filler material (e.g., a metal, a glass, or a
polymer).
[0016] In an example application, the porous oxide membrane or body
may be integrated into an electrochemical energy storage device as
a separator. In this case, a polymer layer may also be deposited
onto the surface of the porous oxide membrane or body (e.g., to
close the pores of the porous oxide membrane or body to prevent ion
transport at temperatures above a threshold temperature in the
range of about 70.degree. C. to about 130.degree. C.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings are presented to aid in the
description of embodiments of the disclosure and are provided
solely for illustration of the embodiments and not limitation
thereof. Unless otherwise stated or implied by context, different
hatchings, shadings, and/or fill patterns in the drawings are meant
only to draw contrast between different components, elements,
features, etc., and are not meant to convey the use of particular
materials, colors, or other properties that may be defined outside
of the present disclosure for the specific pattern employed.
[0018] FIGS. 1A-1G, 2A-2C, 3, 4A-4C, 5, 6A-6C, 7, 8A-8B, 9A-9B, and
10A-10C illustrate examples of nanowire (small wire) formations,
modifications, and characterizations.
[0019] FIGS. 11A-11C and 12A-12C illustrate other example aspects
of nanowire formation.
[0020] FIGS. 13-17 illustrate example methods and modifications of
alkoxide and oxide nanowires (small wires) and porous oxide
materials.
[0021] FIGS. 18A-18E, 19, and 20 illustrate various aspects and
characterizations of the formation of porous oxide membranes and
bulk samples out of nanowires (small wires) and the formation of
composites comprising these oxide materials.
DETAILED DESCRIPTION
[0022] Aspects of the present invention are disclosed in the
following description and related drawings directed to specific
embodiments of the invention. The term "embodiments of the
invention" does not require that all embodiments of the invention
include the discussed feature, advantage, process, or mode of
operation, and alternate embodiments may be devised without
departing from the scope of the invention. Additionally, well-known
elements of the invention may not be described in detail or may be
omitted so as not to obscure other, more relevant details.
[0023] While the description below may describe certain examples in
the context of aluminum-(Al) or oxygen-(O) comprising small
(nano)wires, whiskers, fibers, and other elongated particles, as
well as various porous materials (including porous elongated
particles), it will be appreciated that various aspects may be
applicable to other compositions.
[0024] The description below may describe certain examples of the
formation of alkoxides of nonreactive metal(s) (metals and
semimetals that typically exhibit very small reactivity upon direct
contact with alcohols) by forming alloys with significantly more
reactive metals in the context of Al as a nonreactive metal and Li
as a reactive metal. However, it will be appreciated that alkoxides
of many other nonreactive metals (not just Al) or mixtures of
nonreactive metals may be formed using this approach and other
reactive metals (not just Li) and reactive metal mixtures may be
utilized as alloy elements.
[0025] While the description below also may describe certain
examples of the formation of certain organometallic compounds of
nonreactive metal(s) in the context of alkoxides, it will be
appreciated that various aspects of the present disclosure may be
applicable to other organometallic (metalorganic) compounds, where
alloys of nonreactive metals with reactive metals (e.g., metals
having a reactivity, with respect to a given organic compound, that
is preferably 5 times higher or more than the reactivity of the
nonreactive metals) are used in the synthesis instead of pure
nonreactive metals (or instead of their salts and other compounds).
Similarly, the solubility of metalorganic compound(s) of reactive
metals in the organic solvent (or solvent mix) used in the reaction
may preferably be 5 times higher or more than the solubility of the
metalorganic compound(s) of nonreactive metals in this solvent.
[0026] While the description below also may describe certain
examples in the context of the formation of certain oxides of
metal(s) (of various particle shapes as well as porous bulk
materials), it will be appreciated that various aspects of the
present disclosure may be applicable to the formation of other
ceramic materials (not necessarily oxides, but also fluorides,
oxy-fluorides, carbides, oxy-carbides, nitrides, oxy-nitrides,
phosphides, oxy-phosphides, sulfides, selenides, and others) as
well as metals and metal alloys.
[0027] For simplicity and illustration purposes, all elongated
particles of suitable size, shape, aspect ratios, density,
porosity, crystal structure, and morphology may be generally
referred to herein as "small wires." In various aspects of the
present disclosure, the suitable diameter (or width) of individual
small wires may range from around 2 nm to around 10 microns and the
suitable length of individual small wires may range from around 50
nm to around 50 mm. The suitable aspect ratio (width-to-length) of
individual small wires may range from around 1:4 to around
1:10,000,000. Depending on the application, the suitable true
density (taking into consideration closed porosity) may range from
around 0.1 to around 4 g/cm.sup.3 (for small wires comprising only
Al metal in their composition) and to around 7 g/cm.sup.3 (for
small wires comprising metals other than Al in their composition).
Depending on the application and the processing conditions, the
suitable pore volume within individual small wires may range from
around 0 to around 5 cm.sup.3/g. Depending on the application and
the processing conditions, the microstructure may range from
amorphous to nanocrystalline to polycrystalline to single
crystalline to a mixture of those to other types. Depending on the
application and synthesis conditions, the suitable surface
roughness of the small wires may range from around 0 to around 50
nm.
[0028] Conventional techniques for the synthesis of ceramic
nanowires, whiskers, and fibers include catalyst-assisted chemical
vapor deposition (CVD), cylindrical template-based synthesis,
hydrothermal synthesis, electrospinning, formation of small rolls
from platelets, and others. Such techniques typically suffer from
high cost and small yield (particularly in the case of CVD,
electrospinning, and hydrothermal synthesis at high pressures),
often short length and low aspect ratio of the elongated particles
(particularly in the case of rolling platelets and hydrothermal
syntheses), poor control over the dimensions (diameter and length)
of the elongated particles, often the inability to produce porous
elongated particles with high aspect ratios, limited (or the lack
of) control in porosity and surface morphology of elongated
particles, and other limitations.
[0029] Carbon nanotubes (CNTs) are typically used as conventional
fillers for many polymer and metal composites to improve various
mechanical and other properties. However, CNTs are difficult to
disperse uniformly and are difficult to form an interface having
controllable strength therewith. In addition, they are not
transparent and are typically electrically conductive (which may be
undesirable for some applications), suffer from poor thermal
stability in oxygen-containing environments (due to oxidation), and
have other limitations.
[0030] The present disclosure offers routes to overcome (or
significantly reduce) the above limitations.
[0031] Conventional production of many metal alkoxides (e.g.,
aluminum alkoxides) as well as many other metalorganic compounds
typically requires the use of catalysts. For example, formation of
aluminum ethoxide (Al(EtO).sub.3) and aluminum isopropoxide
(Al(i-PrO).sub.3) typically requires the use of HgCl.sub.2,
I.sub.2, AlCl.sub.3, FeCl.sub.3, SnCl.sub.4, or B.sub.2O.sub.3
catalysts (some of which are toxic and corrosive). This makes the
synthesis process relatively expensive, requires additional
purification steps, and limits the purity of the end result.
[0032] The present disclosure describes examples of methods for a
low cost and large volume (bulk) production of these materials.
Furthermore, it provides avenues for the formation of
organometallic compounds (for example, aluminum alkoxides) in the
form of elongated particles (which are referred to herein as "small
wires") of controlled dimensions and high aspect ratios. This may
be attractive for different applications, including those that
involve further chemical modifications of these materials to
produce other materials (such as metal (e.g., Al) oxyhydroxides,
hydroxides, oxides, oxy-halides, halides, oxy-carbides, carbides,
nitrides, oxy-nitrides, phosphides, oxy-phosphides, sulfides,
selenides, tellurides, and various mixed ceramics and doped ceramic
materials, among others, to name a few examples) in the form of
high surface area small wires as well as membranes and various
porous structures having high specific surface area (e.g., from
around 1 to around 3,000 m.sup.2/g) and other useful properties
(e.g., high strength, high toughness, high activity, high thermal
stability, low thermal expansion, high surface area, etc.,
depending on the final material form).
[0033] In one illustrative example, aluminum alkoxides may be
produced by the reaction of an Al alloy of a suitable composition
with an alcohol. Suitable Al alloy compositions may include both
aluminum and a significant atomic fraction (e.g., typically greater
than 40 at. %) of a metal that is highly reactive with alcohols,
forming, for example, alkoxides of the corresponding metal. It is
typically preferable that these reaction product(s) (metal
alkoxides) be dissolved in the alcohol solution during the reaction
while having a majority of the aluminum alkoxide product remaining
undissolved (which would typically require these metal alkoxides to
have significantly higher solubility than aluminum alkoxide,
preferably by at least 5 times higher or more; even more preferably
50 times higher or more). Reactivity of metals (or materials, in
general) as well as their solubility depends not only on the
element, but also on the solvent (such as an organic compound or
water or their mixture) and the reaction temperature and pressure.
However, for many solvents and for moderate temperatures (e.g.,
0-100.degree. C.) and for near atmospheric pressures some of the
metals (electropositive elements) may typically be relatively
reactive. Examples of such reactive metals include, but are not
limited to, alkali metals (e.g., Li, Na, K, etc.) and alkaline
earth metals (e.g., Ca, Mg, Sr, Be, etc.), to provide a few
examples. Combinations of the reactive metals may also be used in
the alloy. In a more particular example, an aluminum-alkali metal
alloy (e.g., aluminum-lithium alloy) may react with an alcohol
(e.g., with ethanol, methanol, propanol and many others alcohols,
discussed in turn below), forming aluminum alkoxides. This finding
by the inventors was unexpected because Al is generally understood
not to be reactive with alcohols. The inventors hypothesize that
when Al atoms are finely intermixed with more reactive metal atoms
in the alloy (particularly, when aluminum forms intermetallic
compounds (e.g., line compounds in the corresponding phase
diagrams) with such elements), formation of aluminum alkoxide
becomes possible. In addition to aluminum alkoxides, such a method
(the use of alloys of "non-reactive" metals with "reactive" metals)
may be suitable for the formation of "non-reactive" or "poorly
reactive" alkoxides of other metals. These include, but are not
limited to, various alkoxides of transition metals (e.g., Ti, V,
Cr, Mn, Fe, Co, Ni, Cu, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Hf, Ta, W,
Re, Os, Ir, Pt, Au, etc.), various poor metals (Al, Zn, Ga, Cd, In,
Sn, Sb, Hg, Tl, Pb, Bi, P, etc.), various rare earth metals (La,
Ce, Gd, etc.), and nonmetals (B, Si, P, As, Ge, Se, Te, etc.).
Similarly, using alloys of nonreactive (or substantially less
reactive) metals with reactive metals (instead of pure nonreactive
metals or their salts and other compounds) may allow low-cost
synthesis of a broad range of other organometallic (or
metalorganic) compounds. Depending on the nature of the
metal-carbon bond, these include, but are not limited to: (i)
various ionic organometallic compounds, (ii) various organometallic
compounds containing metal-carbon sigma bonds, (iii) various
ylides, (iv) various organometallic compounds with multicenter
bonds, and (v) various organometallic compounds with pi bonded
ligands, among others. It should be noted, however, that the term
"reactivity" is relative. In some examples, two relatively reactive
metals (for example, Li and Mg) could be utilized to form an alloy
(e.g., Li--Mg alloy), where preferential or faster reaction and
dissolution of Li into selected organic solvents (such as alcohols)
may lead to a faster formation of Mg-containing organometallic
nanostructures (such as Mg alkoxides). If the amount of solvent is
limited, Mg (in this example) organometallic dissolution may be
minimized in order to separate solid Mg-containing compounds (such
as Mg-containing nanostructures).
[0034] Returning to the example of exposure of the aluminum alloy
to an alcohol, the formation of aluminum alkoxides and reactive
metal (e.g., alkali metal) alkoxides may take place. In the
simplest case, such a reaction may proceed in a liquid phase (e.g.,
in an alcohol or an alcohol-comprising solution). The reaction
temperature may vary in a broad range from around the freezing
point of the alcohol (or alcohol-comprising solution) to above the
boiling point of the alcohol (or alcohol-comprising solution). If
the reaction proceeds at above atmospheric pressure, the
temperature of the reaction may be increased to significantly above
the boiling point of the alcohol (or alcohol-comprising solution).
Overall, depending on the synthesis conditions, alcohols, the
desired form of the final compounds (alkoxides), and thermal
stability of the alkoxides, the suitable temperature range may vary
from around -120.degree. C. to around +1000.degree. C. Lower
temperatures typically reduce reaction rates and change the
diameter of the resultant small wires. Higher temperatures may
induce melting of alkoxides and too high of a temperature may
induce decomposition of alkoxides. For economic and other reasons,
it may be preferred in some applications to conduct such reactions
at around atmospheric pressure and in a temperature range from
around -20.degree. C. to around +200.degree. C. As will be
discussed below, by changing the reaction temperature, the shape
and morphology of the produced aluminum alkoxide may be tuned as
desired. Upon exposure of aluminum-lithium alloy to an alcohol (or
alcohol-comprising) solution, formation of aluminum alkoxides and
lithium alkoxides was found to take place. Higher solubility of
lithium alkoxides leads to their dissolution into the alcohol or
alcohol-comprising solution. As a result, aluminum alkoxides may be
easily separated from such a solution in the form of the solid
products (e.g., in the form of aluminum alkoxide small wires).
[0035] The suitable composition of such an aluminum alloy may vary.
For example, such an alloy may primarily (e.g., 97-100%) comprise:
(i) aluminum and (ii) reactive metal (e.g., alkali, alkali earth,
or various mixtures of alkali and/or alkali earth elements). As
illustrative examples, an alloy composition may be
Al.sub.0.5Li.sub.0.5 or Al.sub.2Li.sub.3 or Al.sub.4Li.sub.9 or
various other compositions Al.sub.xLi.sub.1-x, where x>0, etc.
In some configurations, it may be preferred that the majority
(50-100%) of alkali metal atoms in the alloy are Li atoms. In the
case of an Al.sub.xLi.sub.1-x alloy, too high of an atomic fraction
of Al atoms (e.g., greater than around 53%) typically leads to a
microstructure comprising a mixture of Al and AlLi phases. If the
size of Al phase grains is large (e.g., greater than around 2-10
nm, depending on reaction conditions), the reaction of the alloy
with a suitable alcohol (or alcohol-comprising) solution may yield
a mixture of Al and Al alkoxides. In some cases (particularly when
the atomic fraction of Al atoms in such an alloy is relatively high
(e.g., greater than around 60%), Al may form an interconnected
porous network, which may be useful for some applications. For
example, formation and further dissolution of Al alkoxide in such
an Al--Al alkoxide composite may yield porous Al, which may also be
a useful product for electronic, energy storage, energy conversion,
energy dampening, and various structural or multifunctional
applications. In cases where the atomic fraction of Al atoms in an
Al.sub.xLi.sub.1-x alloy is reduced and becomes too low (e.g., less
than around 40%), the yield of the Al alkoxide (as the wt. % of the
initial alloy) will naturally be reduced. However, by varying the
relative Al content, one may tune the morphology of the Al alkoxide
products and the rate of the alkoxide formation reaction, which may
be advantageous for industrial production. In addition to using
alloys that primarily (e.g., 97-100%) comprise aluminum and alkali
metal (e.g., Li) atoms, a suitable alloy may also comprise 3% or
more of other elements (e.g., either as impurities or as useful
alloy components).
[0036] As discussed briefly above, another significant advantage of
the disclosed formation of nonreactive metal (e.g., Al) alkoxide
products is that the disclosed process may result in the formation
of elongated particles (small wires) of alkoxides. Furthermore, the
size, morphology, and aspect ratio of such small wires is tunable
in a broad range by changing the synthesis reaction conditions, the
composition of the alloy, and the composition of the reactive
alcohol solution. A low cost, large volume (bulk) production of
alkoxides (or other compounds) of Al or other metals of
controllable (tunable) dimensions may be particularly attractive in
many applications.
[0037] In some applications, it may be advantageous to convert
alkoxide (e.g., aluminum alkoxide) or other metalorganic or
metallic samples into oxide samples. In particular, if the alkoxide
(e.g., aluminum alkoxide) or other metalorganic or metallic samples
are in the form of small wires (either individual or bonded), it
may be advantageous for some applications to transform them into
oxide small wires (either individual or bonded, thus forming a
porous oxide body or a porous oxide membrane). In one example, such
a conversion may take place by heating alkoxide samples in an
oxygen-comprising (or, in some cases, ozone-comprising) gaseous
environment (e.g., in air). Pressure for such a conversion reaction
may vary over a broad range, from around 0.0000000001 atm to around
100,000 atm. Lower pressure typically reduces the reaction rate.
For economical or other reasons, it may be preferred for the
conversion reaction to proceed at around atmospheric pressure.
Suitable reaction temperatures depend on the particular chemistry
of the alkoxide, reaction pressure, the composition of the gaseous
environment, the partial pressure of oxygen, and other parameters.
Higher temperatures increase conversion reaction rates, but may
induce sintering and coarsening of the oxide particles or oxide
melting (which may be undesirable in some applications). Typically,
suitable reaction temperatures are in the range from around
0.degree. C. to around 2000.degree. C. Even more typically,
suitable reaction temperatures are in the range from around
20.degree. C. to around 1500.degree. C. In some applications, it
may be preferable to gradually increase the annealing temperature
in an oxygen-containing environment in order to initially form a
more thermally stable shell around the particles and thus prevent
significant shape change of the alkoxide particles during heating
to higher temperatures (alkoxide particles (small wires) may
otherwise sinter, coarsen, and melt). For example, melting points
of aluminum ethoxide, aluminum methoxide, aluminum propoxide, and
many other aluminum alkoxides is in the range from around 120 to
around 200.degree. C. It is, therefore, advantageous for some
applications to prevent alkoxide small wires from melting during
heating (e.g., by the formation of such a more thermally stable
shell/surface layer). In some applications, such a shape preserving
shell may also be formed prior to heating in a gaseous or liquid
environment. In some applications when formation of porous oxide
membranes or porous oxide bodies is desirable, bonding
(cross-linking or sintering) of individual small wires during
heating may be preferable. As such, depending on the particular
application and the desired end-product, the conditions,
environment, and protocol of the alkoxide-to-oxide conversion
reaction may vary. It is noted that alkoxide-to-oxide conversion
reactions typically lead to a significant volume reduction of the
material. In some applications, such a volume reduction may lead to
the formation of porous oxide samples (e.g., porous oxide small
wires) with either internal (closed) or external (open) pores, or
both. Formation of pores may increase the surface area of the oxide
samples and may also reduce their density, which may be preferred
in some applications.
[0038] In addition to the conversion of various organometallic
compounds to oxides, it may be advantageous for some applications
to convert organometallic compounds (particularly in the form of
small wires or porous materials) into other chemical compounds
(materials), such as metal oxyhydroxides, hydroxides, etc., and
other ceramic materials, such as oxy-halides, halides,
oxy-carbides, carbides, nitrides, oxy-nitrides, phosphides,
oxy-phosphides, sulfides, selenides, tellurides, and various mixed
ceramics and doped ceramic materials, among others, to name a few
examples. It may similarly be advantageous if the shape of the
samples do not change significantly during such transformations.
Like the previously described case of oxide(s) formation, a
similarly broad range of temperatures and pressures and similar
methods may be utilized, depending on the particular chemistry. If
the conversion takes place in a gaseous environment, the
environment may comprise other reactive species with
electronegative ceramic-forming elements instead of (or in addition
to) oxygen-containing reactive gases, such as reactive gases
comprising: halogens (F, Cl, I, Br), sulfur (S), selenium (Se),
nitrogen (N), phosphorous (P), carbon (C), and other
ceramic-forming elements (depending on the desired composition of
the nanostructured ceramic materials).
[0039] In some designs, it may be advantageous to convert species
from the initially formed metalorganic compounds into final
compounds using one or more intermediate steps. For example, in
some applications (e.g., to further produce oxide small wires with
reduced or no porosity (including formation of single crystalline
oxide small wires) during subsequent treatments), it may be
advantageous to convert metalorganic (e.g., alkoxide, such as
aluminum alkoxide) samples (e.g., aluminum alkoxide small wires,
etc.) to oxyhydroxide (e.g., boehmite (AlOOH) or another polymorph
crystalline or amorphous microstructure) or hydroxide (e.g.,
Al(OH).sub.3--having, for example, bayerite, gibbsite,
nordstrandite, pseudoboehmite, or another polymorph microstructure)
samples. In some applications, it may be further advantageous to
preserve the elongated shape and individuality of the small wire
samples during such transformations. In other applications, it may
be advantageous and useful to produce porous structures of
controlled porosity and dimensions from the initial alkoxide small
wires (or porous alkoxide material). Several methods may be
employed for this conversion. For example, one may use a controlled
hydrolysis of aluminium alkoxide samples in water-containing
solvent(s) or water under controlled temperature to produce either
aluminum hydroxide or aluminum oxyhydroxide/monohydroxide AlO(OH)
either of amorphous microstructure (typically at temperatures lower
than around 50-70.degree. C.) or crystalline (e.g., boehmite)
structure (typically at higher temperatures, e.g., at or above
around 70-90.degree. C.). Treatment/reaction time may range from
around 1 minute to around 30 days. Shorter time is typically
difficult to control. Longer time may become less economical. In
some applications, it may be advantageous to heat the water-free
alkoxide powder-comprising solution to the desired temperature
before introducing a water-comprising solution (e.g., also
preheated) to conduct hydrolysis. It may be preferred that this
solution exhibits minimal solubility (e.g., below around 0.02M) for
both the alkoxide and the final product (e.g., oxyhydroxide,
hydroxide, etc.) in order to largely preserve the elongated shape
of the small wires and avoid significant material losses. Alkali
metal alkoxides (e.g., lithium alkoxide) or alkaline earth metal
alkoxides (e.g., magnesium alkoxide or calcium alkoxide) or other
compounds that have higher solubility in these solutions may be
pre-dissolved in them in order to reduce the solubility of aluminum
alkoxides or the final product in these (e.g., in water or
water-containing) solutions. In some applications, it may be
preferred for the alcohol tail(s) of all the alkoxides to be
identical (e.g., if aluminum ethoxides are being transformed it may
be preferred in some applications to use alkali metal ethoxide for
the pre-dissolution in the solution). In some applications, a water
solution in ionic liquids may be used for the transformation
reactions. Once alkoxide samples (e.g., small wires) are first
converted to oxyhydroxide or hydroxide samples (preferably
crystalline small wires), these samples may be further converted to
oxide samples (e.g., oxide small wires) having minimal (or no)
pores and having an ordered crystalline microstructure. By
controlling the concentration of water, the composition of the
reactive solution, and the reaction temperature, one may control
the morphology, chemistry, and crystal structure of the converted
oxyhydroxide or hydroxide samples.
[0040] Changing one or more properties (e.g., increasing pH) of the
water or water-containing solution may be another tool employed for
controlling microstructure, composition, and morphology of the
converted oxyhydroxide or hydroxide samples. LiOH may be used to
increase the pH of the treatment (hydrolysis) solution. KOH or NaOH
or other bases may similarly be used for this purpose. Higher pH
may favor transformation to Al(OH).sub.3. Higher treatment
temperature similarly favors formation of crystalline
microstructure. In some applications, it may be further
advantageous to first transform Al alkoxide particles to AlOOH
before further transforming to Al(OH).sub.3. Similarly, control of
pH (typically in the range from about 5 to about 14) may be
utilized to tune the morphology of other conversion (or
transformation) reaction products as well as the morphology of the
nanostructured materials produced by the selective dissolution of
one (or more) metals from metal alloys.
[0041] In some designs, it may be advantageous to add organic or
inorganic salts or "inert" co-solvents to the "reactive" solvent
(by which it will be understood that "reactive" refers to the
solvent which may form organometallic compounds upon immersion of
the suitable alloy into it) in order to tune the morphology of the
desired organometallic compound (e.g., alkoxide) or in order to
reduce the solubility of at least one of the alloy components. In
some designs, the added salt may comprise the component of the
alloy (e.g., Al salt such as AlCl.sub.3 and others, etc., or Li
salt such as LiCl and others in the case of a reaction with an AlLi
alloy).
[0042] In some designs and alloy compositions, water may be used in
addition to (or instead of) organic solvents to selectively
dissolve one or more metals from metal alloys and produce
nanostructured (porous materials, small wire-shaped particles,
nanoparticles, etc.) metal-comprising compounds of less reactive
metals. A broad range of pressures and temperatures may be
utilized, as described above for the formation of alkoxides.
[0043] In some designs, instead of transforming (converting)
metalorganic small wires (or porous materials) (e.g., formed as
disclosed herein) into oxide or other ceramic small wires or porous
materials by direct (or indirect) transformation reaction(s), one
may transform nanostructured metalorganic compounds into small
metal wires or porous metals. In contrast to conventional methods
for the formation of small metal wires and porous metal structures,
here metalorganic small wires or metal-containing ceramic (e.g.,
oxides, sulfides, nitrides, selected chalcogenides, etc.) small
wires (or the corresponding porous structures) may be first formed
(step A) according to (or conceptually similar to) the
above-discussed methodology and then (step B) reduced to the
corresponding metal form. Such a reduction process may proceed, for
example, by using a gaseous reducing agent or in a liquid
environment by using a liquid reducing agent (e.g. in a solution).
In one example method, formation of the small metal wires (or
porous metal structures) may involve an initial formation of silver
oxide or silver-based metalorganic small wires (or porous
structures) (e.g., by forming Ag--Li, Ag--Na, Ag--Ca, Ag--K,
Ag--Mg, or another suitable Ag alloy and its reaction with a
suitable solvent under suitable conditions to form
silver-containing small wires (or porous structures)), which may be
then transformed into silver oxide wires (e.g., upon annealing in
an oxygen containing environment) and then reduced into small
silver wires. In some cases, metal (e.g., silver) oxide or other
metal ceramic or metal-based metalorganic small wires (or porous
structures) may be directly transformed into metal small wires or
porous metal structures. In some cases, metal (e.g., silver) alloys
may be directly transformed into metal small wires or porous metal
wires or other porous structures upon preferential dissolution of
the more reactive metal into a suitable solvent. Various suitable
organic compounds (solvents) may be used instead (not just suitable
alcohols) for the formation of organometallic wires. Other metal
(not just Ag) and metalloid small wires and porous materials may be
produced similarly. Examples of such metals and metalloids include,
but are not limited to, Au, Pt, Cu, Ti, Ni, Co, Zn, W, Hf, Ta, Nb,
Mo, Ru, Rh, Pd, Bi, La, In, Sn, Ge, and Si, to name a few.
[0044] Such small metal wires may be used in various composites,
optically transparent conductive coatings, as magnetic materials
(in a broad range of applications of soft and hard magnets),
scanning probe microscopy tips, surface enhanced Raman scattering
techniques, metamaterials (negative refractive index materials),
nano-optics, molecular electronics, biological tags, anti-bacterial
materials, field emission electron emitters, gas sensors,
catalysts, electrically conductive additives (e.g., to enhance
electrical conductivity of various paints, plastics, battery or
capacitor or supercapacitor electrodes, etc.), conductive inks,
current collectors and other applications. In some designs, it may
be advantageous for metal small wires (e.g., Cu or Ag and others)
to be incorporated into fabrics to provide antibacterial
properties. In some designs, it may be advantageous for metal small
wires (e.g., Cu or Ag and others) (particularly the small wires
produced according to the disclosed methods herein) to be
components of the anti-static paints, electromagnetic shielding,
conductive inks for touchscreen displays, sensors, smart lenses,
and other applications. In some designs, it may be advantageous for
metal small wires and porous metal structures (particularly those
produced according to the disclosed methods) to be component(s) of
rocket fuel or explosives. Different metals (in the form of porous
structures or small metal wires) may be more effectively utilized
in different applications. For example, small Ta wires and porous
Ta may be particularly attractive for applications in electrolytic
capacitors. In another illustrative example, Cu, Ag, Cu--Ni alloys
and other alloys (in the form of small wires or porous structures)
may be attractive for applications in anti-bacterial coatings or
paints, or anti-bacterial clothing or fabrics. In yet another
illustrative example, Pt, Au, Cu, Ni, and other metal small wires
or porous structures may be particularly effective when utilized as
catalysts. In yet another illustrative example, Au, Cu, Ni, and Ti
small wires may be very effective when used as conductive
additives. Some of these applications (e.g., sensors, molecular
electronics, biological tags, catalyst, etc.) may benefit from the
formation of porous metal wires, which are also enabled by the
disclosed methodology herein. In addition to pure small metal
wires, the described methodology may allow formation of mixed metal
alloys. In this case, alloys of two or more "nonreactive" metals
and one or more "reactive" metals may be used as the initial
materials.
[0045] In addition to the above-discussed solution-based methods
for the formation of nanostructured metal-comprising compounds or
for various transformation reactions, gas phase conversion may also
be utilized in a similar way.
[0046] Several example embodiments and corresponding synthesis
procedures are described, in turn, below. In a first example, the
first synthesis step included formation of .beta.-AlLi by mixing
and melting Al and Li components. Battery grade lithium foil and
0.25 mm thick aluminum foil (either 1145 Al alloy or 99.999% pure
Al, with the results being nearly identical in terms of the
composition and morphology of the final products) were cut into
12.7 mm rounds and Li was sandwiched between Al foils. The mass of
Li in this example was chosen to be approximately 20 wt. % (50 at.
%) of the total (approximately 80 wt. % and 50 at. % of Al) in
order to produce .beta.-AlLi at the congruent melting point. A
graphite crucible was used as a sample holder for melting. Samples
were rapidly heated to 750.degree. C. at a heating rate of
895.degree. C./min in the graphite crucible with an induction
heater. The temperature was measured via an optical pyrometer
during heating. After reaching 750.degree. C. the heating was
stopped immediately while the molten sample was allowed to cool in
an inert environment (Ar gas) at a cooling rate of 150.degree.
C./min.
[0047] The second step included exposure of the AlLi samples to
various solvents (alcohols in this example). More specifically, the
produced AlLi pellet samples were placed in 20 mL of an alcohol in
a glovebox. The chemical reaction resulted in the formation of
hydrogen and possibly other gases, which may be evacuated (e.g.,
via a bubbler) or collected. All solvents selected in this example
were anhydrous alcohols, such as four different homologous series:
various linear chain alcohols (e.g., methanol, ethanol, 1-propanol,
1-butanol, 1-hexanol, 1-octanol, among others), various branched
alcohols (e.g., ethanol, 2-propanol, t-butanol, among others),
various cyclic alcohols (e.g., phenol, among others), and various
multi OH group alcohols (e.g., ethylene glycol, among others). A
low content of water in alcohols was found to be preferable for the
Al alkoxide small wire formation. The maximum tolerable (for small
wire formation) H.sub.2O content in alcohols was found to depend on
the particular alcohol. Typically, it was found that alcohols
should preferably contain below 1000 ppm (often preferably below
100-150 ppm and in some cases (e.g., in the case of ethanol and
other low molecular weight alcohols) preferably below 40-50 ppm) of
moisture to reproducibly yield Al alkoxide in the shape of small
wires. Formation of other metalorganic or metallic nanostructures
(including nanoporous and small wire structures comprising non-Al
metals) may be more tolerant to water content. After completion of
the reaction, solid Al alkoxide products were decanted from the
solution to remove residual LiOH products.
[0048] FIGS. 1A-1E show an example of aluminum ethoxide
(Al(EtOH).sub.3) formation upon exposure of an AlLi alloy sample to
an anhydrous ethanol at low temperatures of 20-60.degree. C. FIGS.
1A-1F show scanning electron microscopy (SEM) images of the various
stages of the small wire formation that starts from the surface of
the AlLi grain and proceeds until all the AlLi grains are
completely converted into Al(EtOH).sub.3 small wires. FIG. 1G shows
a schematic of the process taking place in this example. It can be
seen that the size of the initial AlLi grains (100) affects the
average length of the Al(EtOH).sub.3 small wires (101) produced.
Larger grains typically lead to longer small wires. In addition to
the illustrated schematics, some of the small wires may grow in
between the grains and thus be longer than the average grain
radius.
[0049] SEM image analysis including small wire diameter
measurements were performed manually using open source software
ImageJ. Diameter measurements were performed with a sample size
N.gtoreq.150 for each sample type.
[0050] As small wires form uniformly around the crystalline grains
(see FIGS. 1A-1G), there is evidently no dependence of the wire
formation kinetics on .beta.-AlLi grain orientation and no
preferential growth on specific crystallographic planes. This
suggests that the formation kinetics may be controlled by mass
transport (diffusion). As the wire formation process involves both
the extraction of Li from the .beta.-LiAl alloy (with the
associated tensile stresses at both the surface layer and the
interface with the unreacted alloy) and the insertion of EtO groups
(with the associated compressive stresses), it is believed that
interfacial stresses are responsible for the 1D shape of the
produced Al(EtO).sub.3 products.
[0051] FIGS. 2A-2C show examples of how diameter and specific
surface area of aluminum ethoxide (Al(EtOH).sub.3) small wires may
be tuned (changed) by changing the alcohol composition and
treatment temperatures. Samples exposed to ethanol are labeled with
"E"; to t-buthanol with "T"; and to isopropanol (2-propanol) with
"2P". Room temperature experiments are labeled with "RT", while
AlLi samples treated with alcohols at 60.degree. C. are labeled
with "60C". Overall, FIGS. 2A-2C show an analysis conducted on four
samples produced: (i) E-RT, (ii) E-60C (produced by ethanol
treatment at room temperature and at 60.degree. C.), (iii) T-60C
(produced by t-butanol treatment at 60.degree. C.) and (iv) 2P-60C
(produced by propanol treatment at 60.degree. C.). FIG. 2A shows
the average diameter for Al alkoxide small wires for four of these
samples. Increasing treatment temperature from room temperature to
60.degree. C. increases the average small wire diameter. Changing
the alcohol composition has an even stronger impact on the average
width diameter. FIG. 2B shows a small wire diameter distribution
measured for samples E-60C, T-60C, and 2P-60C. FIG. 2C shows
nitrogen sorption isotherms collected on as-produced samples E-RT,
E-60C, and 2P-60C as well as on the sample E-RT after annealing in
air at temperatures of up to 800.degree. C. FIG. 2C additionally
shows different BET specific surface areas measured on such
samples, showing significant modifications in the porosity, maximum
N2 gas adsorbed, and specific surface area among these samples.
[0052] FIG. 3 shows examples of Fourier transform infrared
spectroscopy (FTIR) measurements on selected small wires produced
in comparison with that of commercially-available aluminum
alkoxides of the corresponding alcohols. An excellent match of the
peak positions is clearly visible. The shift and broadening of the
3340 cm' and 935 cm' peaks to higher and lower frequencies,
respectively, are typical of Al(EtO).sub.3 samples and may suggest
a partial hydrolysis during FTIR analysis.
[0053] FIGS. 4A-4C provide additional characterization of the small
Al(EtO).sub.3 wires formed. FIG. 4A shows an example of high
resolution transmission electron microscopy (HRTEM) studies
confirming a lack of catalysts at the tips of the formed wires and
their amorphous (in this example) morphology. FIG. 4B shows an
example energy dispersive spectroscopy (EDS) analysis, which
confirms the expected chemical composition and the lack of
detectable impurities, although it picked up a Cu signal from the
TEM sample holder. As might be expected from the low melting point
of Al(EtO).sub.3, the heat generated during TEM imaging (300 kV)
was inducing visible damages and shape distortion of the nanowires,
preventing recording of high-resolution micrographs during longer
collection scans and also possibly affecting the electron
diffraction. Thus, X-ray diffraction (XRD) was additionally
conducted. To avoid hydrolysis from air interactions and possible
crystallinity changes during drying of the produced Al(EtO).sub.3
nanowires, the XRD studies were conducted on samples not exposed to
air and suspended in ethanol using a specialized sample holder.
FIG. 4C shows a typical XRD spectrum of the sample. While there is
agreement in the literature on the monoclinic P21/m structure of
Al(EtO).sub.3, there is still a debate on the correct lattice and
unit cell size due to the known difficulty of producing high
quality crystalline Al(EtO).sub.3 samples. Yet, according to a
reference pattern, very broad peaks at around 10 and 22 degr. could
be assigned to diffraction on (001) (10.3 degr.), (20) (20.35
degr.) and (21) (22.7 degr.) planes of Al(EtO).sub.3. Their large
full width at half maximum gives an estimate of the grain size of
only approximately 1.5 nm for the (001) peak, which is considered
to be X-ray amorphous. The mostly amorphous nature of the produced
Al(EtO).sub.3 is very typical, according to the literature.
[0054] FIG. 5 shows examples of in-situ X-ray diffraction (XRD)
studies conducted on an Al(EtO).sub.3 small wire sample (on a Si
wafer substrate) in an oxygen-containing environment (such as air,
in this example). It demonstrates changes in the microstructure of
the sample during heating in air at a heating rate of 4.degree.
C./min. The XRD was performed using 30 min collection times and an
incident angle .OMEGA.=5.degree.. As shown, the formation of clear
.gamma.-Al.sub.2O.sub.3 peaks become visible after the temperature
was increased to around 750.degree. C. in this example.
[0055] FIGS. 6A-6C show different aspects of the formation of an
example flexible, binder-free, nonwoven fabric composed of
.gamma.-Al.sub.2O.sub.3 small wires using a simple tape casting of
the initial Al(EtO).sub.3 small wire suspension in ethanol,
followed by a heat-treatment in air. As discussed above, heat
treatment of Al(EtO).sub.3 nanowires in air at atmospheric pressure
converts them into aluminum oxide (Al.sub.2O.sub.3) wires. FIG. 6A
shows XRD of the samples treated at 700, 750, 800 and 1000.degree.
C. Grazing incidence techniques were used to reduce the X-ray
penetration depth to less than 50 .mu.m to avoid measurements of
the Al.sub.2O.sub.3 heating stage. FIG. 6B shows an SEM image of
the .gamma.-Al.sub.2O.sub.3 wires produced by heat-treatment at
1000.degree. C. No signs of pulverization or significant
microstructure changes compared to the initial Al(EtO).sub.3
samples could be observed. Such morphology retention may be an
advantageous aspect of Al.sub.2O.sub.3 small wire synthesis for
many practical applications. The overall morphology of the produced
nonwoven fabric is somewhat similar to that of paper, where the
cellulose fibers are replaced here with stronger and stiffer
.gamma.-Al.sub.2O.sub.3 small wires. Due to the fibrous nature of
the produced free-standing films and the small diameter of the
.gamma.-Al.sub.2O.sub.3 small wires, they exhibit good flexibility.
This is in sharp contrast to anodized Al.sub.2O.sub.3 membranes of
comparable thickness that are known to be extremely brittle and
difficult to handle. FIG. 6C shows optical images of the nonwoven
fabric composed of .gamma.-Al.sub.2O.sub.3 small wires.
[0056] FIG. 7 shows examples of the formation of porous small wires
after heating Al(EtO).sub.3 small wire samples in air at 600 and
800.degree. C. Transmission electron microscopy (TEM) micrographs
clearly show that initially smooth and nonporous small wires
transformed into nanocrystalline (polycrystalline) porous small
wires. The electron diffraction pattern of the 800.degree.
C.-heated sample corresponds to a .gamma.-Al.sub.2O.sub.3 crystal
structure of the small wires.
[0057] FIGS. 8A-8B show an example of a mechanism that may be
involved in the formation of the small wires during preferential
dissolution of one of the metal alloy components (such as
preferential dissolution of Li from the .beta.-AlLi as Li(EtO) into
ethanol). As noted above, the Al(EtO).sub.3 small wire formation
process involves both the extraction of Li from the .beta.-LiAl
alloy (with the associated tensile stresses at both the surface
layer and the interface with the unreacted alloy) and the insertion
of EtO groups (with the associated compression stresses). The
tensile stresses may induce intermediate formation of nanosized
cracks within the thin Al layer on the .beta.-AlLi surface and the
resultant (crack-separated) nanosized islands. Such islands may
transform into Al(EtO).sub.3 and serve as stable nuclei for further
small wire growth. The anisotropic swelling of the islands during
this chemical transformation reaction by promoting vertical
expansion while suppressing lateral expansion may take place when
there is the formation of a sharp boundary between the transformed
(expanded) and untransformed amorphous segment. In order to
minimize strain energy at the Al/Al(EtO).sub.3 interface, the
transformation-induced strain may be directed normal to this
interface. As the .beta.-AlLi de-lithiation and transformation of
Al.fwdarw.Al(EtO).sub.3 proceeds the strain energy minimization
leads to the Al(EtO).sub.3 expansion in the vertical direction,
leading to the formation of Al(EtO).sub.3 small wires. FIG. 8A
shows a schematic of the proposed formation mechanism and FIG. 8B
illustrates details of the morphological evolution of a
.beta.-AlLi--Al surface region into Al(EtO).sub.3 small wires via
strain energy minimization at the reaction boundary. The large
pores between the individual wires assist with EtOH diffusion
towards the unreacted .beta.-AlLi surface and increase the rate of
the out-diffusion of Li.sup.+ and the reaction products, H.sub.2
and LiEtO. Because of the significant (approximately 600%) overall
volume increase upon transformation of .beta.-AlLi alloy into
Al(EtO).sub.3, the particles increase in diameter.
[0058] Other metalorganic (organometallic) and metallic small wires
may form according to a similar mechanism.
[0059] Formation and size of both the Al and Al alkoxide nuclei in
the example above depends on the interplay between the strain
energy release upon the crack formation and increase in the
interfacial energy. As such, the morphology of the Al alkoxide
surface layer may be influenced by the alcohol composition.
[0060] FIGS. 9A-9B show a table and XRD patterns with examples of
the formation of different (nano)structures upon exposure of
.beta.-AlLi to either water or different alcohols at near room
temperature and at 60.degree. C. Formations of nanowires (NW),
wires, powders and porous materials were observed, depending on the
solvent composition and temperature. Because the mobility of Al'
ions and Al alkoxide molecules increase at higher temperature, the
size of the nuclei and the resultant wire diameter may be
temperature-dependent. Exposure of .beta.-AlLi alloy to larger
molecular weight alcohols (such as i-PrOH, t-BuOH, PhOH, 1-BuOH,
1-HxOH, 1-OXOH, EG, and others) at atmospheric pressure at room
temperature typically resulted in the passivation of the surface
layer and the formation of porous aluminum with varying degrees of
residual 13-AlLi. At room temperature, exposure of .beta.-AlLi to
dry methanol also resulted in the formation of a passivating layer.
At 60.degree. C., EtOH, MeOH, i-PrOH, and t-BuOH yielded Al
alkoxides, while larger i-PrOH and other solvents yielded formation
of porous aluminum with varying degrees of residual
.beta.-AlLi.
[0061] FIGS. 10A-10C show example aspects of the methoxide
Al(MeO).sub.3 structures produced upon exposure of .beta.-AlLi to
smaller (compared to ethanol) methanol molecules at 60.degree. C.
This may be related to the prevention of nano-island (nuclei)
formation in the surface layer due to faster reaction of
delithiated Al with smaller methanol molecules and thus reduced
fracture-inducing surface tensile stresses. Interestingly, the Al
methoxide (Al(MeO).sub.3) sample may typically be in the form of a
crystalline powder at such conditions, while the Al(EtO).sub.3, Al
isopropoxide (Al(i-Pro).sub.3), and Al tert-butoxide
(Al(t-BuO).sub.3) formed nanowires. The high degree of
crystallinity in Al(MeO).sub.3 produced at 60.degree. C. may result
in the formation of cracks or openings at grain boundaries and
prevent the surface passivation. The lack of Al(MeO).sub.3
nanowires in this experiment may be related to their pulverization
due to insufficiently high ductility and elasticity of
Al(MeO).sub.3 required to accommodate chemical
transformation-induced interface stresses of the relatively large
(up to approximately 1 .mu.m) diameter crystals.
[0062] FIGS. 11A-11C show example aspects of the Al isopropoxide
(Al(i-Pro).sub.3) structures produced upon exposure of .beta.-AlLi
to dry isopropanol at atmospheric pressure at 60.degree. C. The
higher temperature allowed reaction of delithiated Al with larger
isopropanol molecules, which successfully converted to 1D
Al(i-PrO).sub.3 nanostructures of approximately 1.1 .mu.m diameter.
Faster diffusion of still moderately sized isopropanol molecules
may have allowed this transformation reaction to proceed. In spite
of the relatively large diameter of Al(i-PrO).sub.3 1D structures,
they did not pulverize into smaller crystals. This may be related
to (i) partial dissolution of Al(i-PrO).sub.3 into i-PrOH (due to
its significantly higher solubility in alcohols compared to that of
Al(MeO).sub.3 and Al(EtO).sub.3) and associated accommodation of
the interface stresses by the dissolution-induced pores, to (ii)
different growth direction and smoother surface (and thus reduced
probability of surface crack formation and propagation), or to
(iii) their slower reaction rate when compared to that of
Al(MeO).sub.3 (and thus lower stress-loading rate, which should
lead to higher fracture toughness). Increasing temperature from 20
to 60.degree. C. approximately doubled the average diameter of the
Al(EtO).sub.3 nanowires from 41 to 78 nm. These analyses
demonstrate the flexibility of the disclosed approach to produce 1D
nanostructures of tunable diameter. The discovered formation of
small wires and other nanostructures via an interplay of the
surface tensile stresses upon the dissolution of one of the alloy
components and strain energy minimization at the chemical
transformation reaction boundary may be applicable for a broad
range of chemistries, thus providing a new methodology for the
low-cost synthesis of 1D (nano)materials and porous materials.
[0063] FIGS. 12A-12C show example aspects of the formation of
Mg(i-PrO).sub.2 wires produced by exposing bulk MgLi alloy to
i-PrOH. Reactivity and solubility of Li in i-PrOH is significantly
higher than that of Mg (even though both are somewhat reactive),
which leads to the selective dissolution of Li (in the form of Li
isopropoxide) and the formation of Mg isopropoxide nanostructures
at atmospheric pressure. Similar to the above-discussed results,
heating Mg(i-PrO).sub.2 in air converts it to MgO.
[0064] In some aspects of the present disclosure, it may be
advantageous to deposit a layer of another material on the surface
of the metal, metal alkoxide, metal hydroxide, metal oxyhydroxide,
metal oxide, and ceramic small wires or porous metal, porous metal
alkoxide, porous metal hydroxide, porous metal oxihydroxide, porous
metal oxide, porous ceramic and other porous materials. This may be
for a desired modification of mechanical properties, modification
of electrical or dielectric properties, modification of interfacial
properties (such as interfacial energy, strength, wetting angle,
tribological properties, etc.) (e.g., if used in composites),
modification of optical properties, protection against undesirable
actions of the outside environment, enabling enhanced chemical
reaction rates (e.g., for catalysis), and other reasons. The
suitable surface layer thickness may range from as thin as
sub-monolayer (discontinuous monolayer, typically 0.01-0.2 nm in
average thickness) to as thick as 1,000 nm. However, an average
layer thickness ranging from around 0.3 nm to around 30 nm has been
found to work well for many applications.
[0065] Depending on the applications of the produced metal,
alkoxide, hydroxide, oxihydroxide, oxide, and ceramic small wires
(or porous materials), the layer may be a metal, polymer, carbon,
dielectric, or ceramic material. Examples of suitable ceramic
surface layers include, but are not limited to, various oxides,
various chalcogenides (e.g., sulfides) and oxi-chalcogenides,
various halides (e.g., fluorides) and oxi-halides, various nitrides
and oxi-nitrides, various carbides and oxi-carbides, various
borides, their mixtures, and others. In some applications, it may
also be advantageous to form a composite surface layer coating. In
some applications, it may also be advantageous to form a porous
coating layer. The pores in the coating layer may be filled with
another functional material. In some applications, the coating
layer may leave closed pores within the porous alkoxide, hydroxide,
oxihydroxide, and oxide materials (e.g., small wires). In some
applications, these closed pores may be filled (pre-filled) with
another functional material. In some applications, the pores may
also be open.
[0066] In some applications, it may be advantageous to put two or
more layers of materials as a coating. These layers may have
different composition, density, porosity, surface chemistry,
mechanical or electrical or optical properties, or other
substantial differences. For example, if the inner alkoxide,
hydroxide, oxihydroxide and oxide materials (e.g., small wires)
have internal porosity, the inner layer of the coating may have
smaller pores and the outer layer of the coating may have no
pores.
[0067] Different methods may be suitable for the formation of
surface layers on alkoxide, hydroxide, oxihydroxide, and oxide
materials (e.g., small wires or porous materials). These include,
but are not limited to: conversion and deposition reactions
conducted in gaseous or liquid environments and their combinations.
Examples of suitable deposition methods in a gaseous phase include,
but are not limited to, various types of chemical vapor deposition
(CVD) (including plasma enhanced deposition), atomic layer
deposition (ALD), molecular beam epitaxy (MBE), physical vapor
deposition (PVD, such as sputtering, pulsed laser deposition,
thermal evaporation, etc.), and their various combinations. CVD and
ALD may be preferable in some applications requiring more conformal
and more uniform (yet relatively economical) deposition. Examples
of suitable liquid phase depositions include, but are not limited
to: electrodeposition, plating, electrophoretic deposition,
layer-by-layer deposition, sol-gel, chemical solution deposition or
chemical bath deposition (CSD or CBD), and others.
[0068] FIGS. 13-15 and 17 show example processes for the
manufacturing of the disclosed small wires and selected functional
materials from the disclosed small wires.
[0069] FIG. 13 shows an example process for the formation of
alkoxides, such as aluminum alkoxides, as an example organometallic
(or metalorganic) compound among others (including alkoxides having
the shape of small wires). Active (in terms of its high reactivity
with a selected alcohol) and inactive (in terms of its very low
reactivity with a selected alcohol) materials are selected (block
1301a) along with a suitable alcohol (block 1301b). Such materials
are then formed or otherwise produced into an alloy of a suitable
composition (typically with the atomic fraction of active materials
being greater than around 40%) (e.g., by heat treatment (e.g.,
using an inductive furnace), chemo-mechanical fusion,
electrochemical alloying, or by other methods) (block 1302). It
will be appreciated that "providing" or "producing" the alloy as
used herein may encompass not only active processing steps, but
also generally any method of procuring the alloy, including
obtaining it from a third party and so on. The produced alloy is
then subjected to treatment in a selected alcohol or a suitable
alcohol-comprising solution in order to produce solid alkoxides of
the inactive material (block 1303). Preferably, alkoxides of the
active material are simultaneously dissolved in the alcohol or a
suitable alcohol-containing solution. The solution may preferably
have nearly no reactivity with the produced alkoxides of the
inactive materials and may preferably not dissolve the produced
alkoxides of the inactive materials. The solid alkoxides of the
inactive material (e.g., in the form of small wires) may then be
separated from the solution (e.g., by filtering, centrifugation,
decanting, or other methods) (block 1304). The surface of the
produced alkoxides may optionally be cleaned (e.g., by washing in
alcohol(s) or other non-reactive solvents) (optional block 1305)
and optionally dispersed in a solvent (optional block 1306). If a
surfactant is used for the dispersion step, it may be important
that it does not destroy the alkoxides by a chemical reaction
(chemical attack). If a sonication is used for this dispersion
step, it may also be important to use sufficiently low power to
prevent undesirable breaking of the alkoxide particles (small
wires). In addition to the alkoxide formation, a similar method may
be utilized for the formation of other metalorganic structures as
well as metal structures (such as porous and small wire-shaped
structures), depending on the solvent chemistry and environmental
conditions. The surface of the formed (e.g., alkoxide) particles
(small wires) or porous structures may be optionally chemically
modified or coated with a functional layer of suitable thickness
and composition (depending on the application) (optional block
1307). The alkoxide particles (small wires) or porous structures
may be optionally transformed to hydroxides and oxihydroxides
(optional block 1308) prior to their final conversion to oxide
small wires or porous oxide materials (block 1309). As discussed
above, the conversion (block 1309) to oxide may proceed by heating
of the precursor small wires in an oxygen containing gas (such as
air). In addition to the oxide formation, other ceramic small wires
may be produced by utilizing other reactive gases (e.g.,
halogen-containing or nitrogen-containing, to provide a few
examples) or reactive solutions. For treatment in a gaseous
environment, plasma may be effectively utilized to increase the
conversion rate (particularly at lower temperatures).
[0070] FIG. 14 shows an example process for the formation of a
broad class of organometallic (or metalorganic) compounds
comprising metals that typically exhibit very low reactivity with
the corresponding organic species (ligands). Active (in terms of
its high reactivity with a selected organic compound) and inactive
(in terms of its very low reactivity with a selected organic
compound) materials are selected (block 1401a) along with a
suitable organic solvent/compound (block 1401b), and then formed or
otherwise produced into an alloy of a suitable composition
(typically with the atomic fraction of active materials being
greater than around 40%) (block 1402). It will again be appreciated
that "providing" or "producing" the alloy as used herein may
encompass not only active processing steps, but also generally any
method of procuring the alloy, including obtaining it from a third
party and so on. The produced alloy is then subjected to treatment
in the selected organic compound or a suitable solution comprising
the desired organic compound in order to produce solid metalorganic
(or organometallic) compounds of the inactive material (block
1403). Preferably, metalorganic (or organometallic) compound(s) of
the active material are simultaneously dissolved in the solution.
The solution may preferably have nearly no reactivity with the
produced metalorganic (or organometallic) compound(s) of the
inactive materials and may preferably not dissolve the produced
metalorganic compound(s) of the inactive materials. The solid
metalorganic (or organometallic) compound(s) comprising the
inactive material may then be separated from the solution (block
1404). The surface of the produced metalorganic (or organometallic)
compound(s) may optionally be cleaned (e.g., by washing in
alcohol(s) or other non-reactive solvents) (optional block
1405).
[0071] As discussed above, instead of using organic solvents as
shown in FIG. 14, one may also use water or aqueous solution (of
various pH and composition (typically in the pH range from around 4
to around 14), including those that comprise metal salts, metal
bases or acids) for the selective (preferential) dissolution of one
(or more) (more reactive) components of the metal alloys and
relatively fast formation of nanostructures (e.g., small wires,
porous small wires, other porous structures, particles of
controlled dimensions, etc.) comprising less reactive metals.
Depending on the alloy composition and pH, one may produce useful
nanostructures (e.g., small wires, porous structures, particles of
controlled dimensions, etc.) of metals, metal hydroxides, metal
oxyhydroxides, metal oxides, and other metal-comprising species.
Higher pH and higher nobility of the less reactive metals in the
alloys (of the more reactive and less reactive metals) may
typically favor formation of metallic compounds. Examples of more
noble metals suitable for the formation of nanostructured metallic
compounds include, but are not limited to, palladium, platinum,
gold, silver, titanium, copper, lead, molybdenum, uranium, niobium,
tungsten, tin, tantalum, chromium, nickel, and their various
alloys. In some designs, the produced small wires may be
porous.
[0072] In some designs, it may be advantageous to utilize alloys
(of more reactive and less reactive metals) in the form of the
wires of well-defined dimensions, various porous structures of the
desired pore size (e.g., a mesh or a foam) or particles of
well-defined size and shape (e.g., spherical particles or
wire-shaped particles) prior to the selective dissolution
procedure. The size (e.g., diameter) of such particles may range
from around 0.1 microns to around 10,000 microns, depending on the
application. This method may allow formation of nanostructured or
porous particles of less reactive metal (or less reactive metal
compounds) with hierarchical morphology and additional control of
their structure, dimensions, and properties.
[0073] Formation of porous nanostructures (including flexible
porous structures, such as flexible membranes) comprising metal or
ceramic compositions may be particularly attractive for some
applications.
[0074] FIG. 15 shows an example process for the formation of porous
oxide membrane(s) or porous oxide bodies of the desired shape. The
process starts with providing alkoxide small wires (block 1501),
which may be synthesized according to part of the process described
in FIG. 13 (blocks 1301-1304). These small wires may be optionally
dispersed (optional block 1502), optionally converted to hydroxide
or oxihydroxide small wires (optional block 1503) and deposited on
a substrate to form a (e.g., non-woven) film or a sheet (somewhat
similar to a paper formation process except that cellulose fibers
are replaced here with alkoxide small wires) (block 1504). In some
applications, one may introduce a charge on the surface of the
small wires and collect such small wires by application of an
electric field (e.g., by applying an opposite potential to a
substrate to attract these small wires). A field-assisted
deposition may proceed in either liquid (when small wires are
dispersed in a liquid) or in gaseous phases (when small wires are
carried with the flow of gas), or by a hybrid technique (e.g., by
electrospray deposition) or by combination(s) of these and other
techniques. Small wires may also be deposited by using a spray
deposition method, by electrophoretic deposition, by voltage
assisted deposition from gaseous suspension or liquid or aerosol
suspension, by casting from a liquid suspension, by layer-by-layer
deposition, or by dip coating, to name a few suitable methods.
Porosity may be further enhanced in such small wire-based membranes
when small wires are deposited together with another sacrificial
material (e.g., a salt, a polymer, or a suitable oxide, etc.) to
form a membrane sample of the desired dimensions when this
sacrificial material is at least partially removed (e.g., by
dissolution, etching, oxidation, or other suitable methods). In
some cases, stretching may also be utilized for a porosity
enhancement. In some applications that require formation of bulk
(as opposed to thin (e.g., 10 nm-0.5 mm) membranes or sheets)
porous oxides, the small wires may be formed into a body of the
desired shape (e.g., by using a mold filled with such small wires)
(block 1504). In order to increase the density of the deposited
small wires, they may be deposited in an aligned form. A flow of
the small wire suspension may be used to orient such small wires
prior (or during) the deposition. Alternatively, an electric field
may be used for small wire orientation. Deposited small wires may
also be optionally compacted (compressed) to a desired density
(optional block 1505). In some cases, it may be advantageous to add
another material (e.g., one that would assist bonding of the
individual small wires) to the assembly of small wires (optional
block 1506). Such a material may be a polymer, a salt, or an oxide
precursor (e.g., hydroxide or oxihydroxide) and may comprise the
same metal as the small wires. Such a material may be sprayed into
the sheet, for example, by using jets of air or a compatible gas or
liquid to provide better structural properties to the film. In some
cases, this material may be deposited in the form of the fibers.
The final step may involve transformation of the deposited small
wires to a porous flexible oxide membrane or a porous bulk body,
composed of the oxide small wires bonded together (either by
chemical or physical bonds) (block 1507). As described above,
treatment in oxygen-containing gas (e.g., in air) may be utilized
for such a transformation. In some designs, instead of formation of
oxide (block 1507), an oxy-halide (e.g., oxy-fluoride) or halide
(e.g., fluoride) or other flexible ceramic membrane or porous body
may be formed. In some designs, conversion to oxide or another
ceramic material may be conducted in plasma. The pores in the
produced porous oxide material (e.g., aluminum oxide) or porous
ceramic material (e.g., aluminum oxy-fluoride or aluminum fluoride
or oxyfluoride or fluoride of another metal or carbide, etc.) may
be optionally partially or completely infiltrated with another
material (e.g., polymer, metal, ceramic, glass, composite,
functional particles, etc.) to form a composite with the desired
properties (optional block 1508). The surface of the small wires
(before or after conversion to oxide or another ceramic material)
may be optionally coated (pre-coated) with a surface layer. In some
designs, plasma or heat-treatment in a controlled environment may
be involved in the surface layer formation. The suitable mass and
volume fractions of the small wires in such composites depend on
the particular application, desired properties, and compaction of
the small wires. This typically ranges from around 0.0001 vol. %
(and around 0.001 wt. %) to around 90 vol. % (and around 90 wt.
%).
[0075] FIG. 16 shows an example of a porous Al.sub.2O.sub.3
membrane produced according to the process illustrated in FIG. 15,
where small Al ethoxide wires are first produced according to the
process illustrated in FIG. 13. These small Al ethoxide wires were
first dispersed in an ethanol solution and deposited on a
polytetrafluoroethylene (PTFE) substrate by casting to form a
porous sheet. By heating this sample in dry air at elevated
temperatures (more specifically, by heating in air from room
temperature to 800.degree. C. at a rate of 5.degree. C./min,
holding at 800.degree. C. for 2 hours, and cooling to room
temperature), a flexible porous Al.sub.2O.sub.3 membrane was
obtained.
[0076] In some applications, it may be advantageous for the porous
oxide (or porous ceramic) material to be composed of individual
layers. It may also be advantageous to exhibit a horizontal (or
vertical) alignment of the small wires within an individual layer.
In some applications, it may be advantageous for the horizontally
aligned small wires to have a different orientation in the
subsequent layers (e.g., with an angle anywhere between 0 and 90
degrees in the neighboring layers). Controlling orientation of
individual layers provides opportunities to tailor the mechanical
properties of the composites in multiple directions and have a
different resistance to fracture and tunable bending modulus.
[0077] FIG. 17 shows an example process for the formation of a
multi-layered porous membrane or a composite comprising a
multi-layered porous membrane. Within individual layers, the small
wires may be aligned along certain directions or be misaligned.
This example process involves providing oxide (or other ceramic) or
metallic small wires (block 1701), which may be produced, for
example, as described in FIG. 13. These small wires may be
deposited on a substrate aligned along the desired direction (block
1702) (e.g., forming a pattern 1702-1, shown schematically as
parallel lines). After an optional heat-treatment (optional block
1703) and optional compaction of the small wires in this layer, a
second layer of aligned small wires may be deposited on the top of
the first layer (block 1704) (e.g., forming a pattern 1704-1, shown
schematically as intersecting lines), and the whole assembly may
also be further optionally heat-treated (optional block 1705) and
optionally compacted. The deposition of individual layers of
aligned (or misaligned) small wires may be repeated multiple times
until the desired thickness and the desired number of layers is
obtained (optional block 1706). After optional heat treatment
(optional block 1707), optional compaction, and optional deposition
of the functional surface coating(s) (optional block 1708), the
multi-layered assembly of small wires may optionally be partially
or fully infiltrated with another material (e.g., polymer, metal,
ceramic, glass, composite, functional particles, etc.) to form a
composite with the desired properties (optional block 1709) (e.g.,
forming a pattern 1709-1, shown schematically as filled
intersecting lines). Such a composite may be flexible, have
enhanced mechanical or desired optical properties, or other
attractive features. The suitable mass and volume fractions of the
small wires in such composites will depend on the particular
application, desired properties, and compaction of the small wires.
This typically ranges from around 0.0001 vol. % (and around 0.001
wt. %) to around 90 vol. % (and around 90 wt. %).
[0078] Other aspects of the present disclosure include the use of
oxide (or other ceramic) small wires and porous oxide (or other
porous ceramic) materials in several applications. Such uses may
provide unique benefits of achieving attractive (and sometimes
remarkable) properties at a low cost.
[0079] One aspect of the present disclosure includes the use of
aluminum oxide (and other oxide as well as other ceramic) small
wires (particularly those described herein, including but not
limited to porous aluminum oxide small wires) in biocompatible
materials. In this case, the utilization of such small wires may
favorably enhance chemical, biological, physical, and structural
(mechanical) properties, allow control over permeation (of species
of interest), control density and/or enhance compatibility with the
surrounding host tissues. Depending on the particular application,
mechanical properties of interest may include: higher elastic
modulus, higher strength, higher hardness, higher wear resistance,
higher stiffness, higher toughness, or optimal load transmission.
Example applications may include, but are not limited to,
composites for (i) external fixators, bone plates, and screws
(including those that comprise epoxide, poly(methyl methacrylate),
polypropylene, polyethylene, PS, nylon, polybutylterephthalate,
polyether ether ketone, and other polymers or titanium, various
titanium alloys (e.g., titanium aluminum, titanium aluminum
vanadium, titanium aluminum niobium, titanium molybdenum, gold,
biocompatible stainless steel (e.g., 316LL),
cobalt-chromium-molybdenum alloys, or other biocompatible metals
and/or carbon); (ii) joint replacement (including those that
comprise examples of polymers, metals, and carbon above); (iii)
total hip replacement; (iv) bone cement; (v) dental applications;
(vi) catheters; and (vii) prosthetic limbs, to name a few. In
addition, the described aluminum oxide nano small wires may be
advantageously utilized in superparamagnetic nanocomposites for
biology, medicine, diagnostics, and therapy. The suitable volume
fraction of small wires in biomaterial composites may range from
around 0.5 vol. % to around 70 vol. %.
[0080] In some applications (e.g., transparent armor, screens,
windshields, displays, among others), the use of aluminum oxide
(and other oxide and other optically transparent ceramic) small
wires (particularly those described herein) as fillers in optically
transparent glasses and glass coatings may be highly advantageous
in terms of tuning glass optical properties, increasing glass
hardness, wear resistance, scratch resistance, fracture toughness,
manufacturability in thin sheet states, and other important
properties. When small wires are small in dimensions (e.g., below
around 50-100 nm in diameter) and uniformly distributed within a
glass, scattering of visible light might be avoided even if the
glass matrix exhibits a substantially different refractive index
because optical non-uniformities may be sufficiently below half of
the visible light wavelengths. However, if optical non-uniformities
are larger than around 100 nm, matching the refractive index of the
small wires with that of glass may be important to maximize
transparency of the small wire-glass composites. This may be
accomplished either by tuning the refractive index of a glass or by
tuning the refractive index of the small wires. For example, if
small wires are composed of 100% solid Al.sub.2O.sub.3 small wires
with no closed pores they would typically exhibit a refractive
index of around n=1.75-1.81 (for visible light). As such, selecting
a glass (ceramic) that approximately (preferably within 4% or less;
more preferably within 2% or less; or even more preferably within
1% or less) matches its refractive index n may be advantageous for
maximizing transparency of the Al.sub.2O.sub.3 small wire/glass
composites. Illustrative examples of such glasses with matching
refractive index may include, but are not limited to, various flint
glasses, beryllium oxides, magnesium oxides, various suitable
mixtures of oxides comprising at least two (preferably at least
three; or even more preferably at least four) of the following
oxides: boron oxide, barium oxide, beryllium oxides, bismuth oxide,
magnesium oxides, calcium oxide, cesium oxide, rubidium oxide,
potassium oxide, aluminum oxide, lanthanum oxide, cerium oxide,
lithium oxide, magnesium oxide, manganese oxide, sodium oxide,
niobium oxide, neodymium oxide, phosphorous oxide, antimony oxide,
silicon oxide, germanium oxide, strontium oxide, tin oxide,
titanium oxide, tantalum oxide, hafnium oxide, tungsten oxide, zinc
oxide, and zirconium oxide. Examples of suitable commercial glasses
include but are not limited to N-BASF64 with n=1.7, N-LAK8 with
n=1.72, N-SF18 with n=1.72, N-SF10 with n=1.73, S-TIH13 with
n=1.74, N-SF11 with n=1.78, N-SF56 with n=1.78, N-LASF44 with
n=1.8, N-SF6 with n=1.81, N-SF57 with n=1.85, N-LASF9 with n=1.85,
and many others). In another embodiment, for a given refractive
index of a glass (e.g., aluminosilicate-type glass) of, for
example, 1.52, a closed internal porosity of porous Al.sub.2O.sub.3
small wires may be tuned in order to achieve a matching refractive
index (preferably within 4% or less; more preferably within 2% or
less; or even more preferably within 1% or less). By increasing the
closed pore volume within porous Al.sub.2O.sub.3 small wires, one
may reduce their effective refractive index from around n=1.75-1.81
to below 1.3, in some applications. In some applications, optically
transparent polymers (e.g., particularly those that exhibit a high
refractive index, such as polycarbonate, trivex, crown glass, etc.)
may be utilized instead of oxide glasses or optically transparent
ceramic materials as matrix materials in Al.sub.2O.sub.3 small
wire-comprising composites. Porous oxide particles (not only
Al.sub.2O.sub.3) with matching effective refractive index may also
be used in optically transparent polymer-oxide composites that
exhibit more favorable mechanical properties and scratch resistance
than pure polymers. In some applications of transparent materials
with enhanced toughness and scratch resistance, polymer small wire,
glass small wire, and ceramic small wire composites may be
manufactured by first producing a porous scaffold (including both
bulk parts of various shapes and sizes and porous sheets or thin
membranes) composed of the small wire material that is then
infiltrated with a matrix material (such as a suitable polymer,
oxide glass, transparent ceramic, etc.). The suitable mass and
volume fractions of the small wires in such wire-glass composites
typically ranges from around 0.01 vol. % (and around 0.01 wt. %) to
around 85 vol. % (and around 85 wt. %).
[0081] Examples of suitable uses of such glass small wire
composites include, but are not limited to, watches,
screens/monitors of various sizes (e.g., computer monitors, cell
phone screens, monitors in laptops, ultrabooks, tablets, electronic
books, television screens, credit card terminals, monitors of
various other electronic devices or components of devices, etc.),
various optical lenses (including those used in glasses, cameras,
microscopes, spectroscopes and other research tools, etc.),
sensors, window glasses, various applications in automotive and
transport (windscreens/windshields, backlights, light-weight but
reinforced structural components of cars, aircrafts, ships, etc.),
various appliances (oven doors, cook tops, etc.), glass bulbs,
tableware glass (e.g., drinking glasses, plates, cups, bowls,
etc.), jewelry, protection equipment (transparent armor, safety
screens, helmets, personal protection equipment, radiation
protection screens (e.g., from X-Rays, gamma-rays, etc.)), various
interior design and furniture (mirrors, partitions, balustrades,
tables, shelves, lighting, etc.), various reinforcement structures,
packaging, fiber optic cables, life science engineering, and
electrical insulation, to name a few.
[0082] In some applications, it may be advantageous to add a
particular color to otherwise transparent oxide small wire/glass
composites or to the small wires themselves. In some applications,
suitable dyes or quantum dots may be attached to the surface of the
small wires or be infiltrated into the pores (if present in the
small wires). In some applications, it may be advantageous to seal
these pores in order to prevent direct contact between the dyes (or
quantum dots) and surrounding environment. In some applications,
the sealing material may be a glass (e.g., oxide glass, etc.) or a
ceramic or a polymer.
[0083] In some applications, the use of aluminum oxide (and other
oxide and other ceramic) small wires (particularly those described
herein, including but not limited to porous aluminum oxide small
wires) as well as aluminum oxide (and other oxide based and other
ceramic based) porous membranes as fillers in polymer composites
(including various polymer-ceramic, polymer-carbon, polymer-metal,
polymer-ceramic-metal composites) may be advantageous for enhancing
various properties (e.g., mechanical, thermal, dielectrical, etc.)
of such polymer-comprising composites. The one dimensional (1D)
wire geometry may be particularly advantageous for the formation of
dense composites with excellent mechanical properties, flexibility,
uniformity and controlled (e.g., either high, medium, or low)
volume fraction of the small wires. Depending on the particular
application, mechanical properties of interest (at room
temperature, elevated temperatures, or low temperatures) may
include, but are not limited to: higher elastic modulus, higher
strength, higher hardness, higher scratch resistance, higher wear
resistance, higher stiffness, higher toughness, better resistance
to creep, better resistance to fatigue, and better tribological
properties, to name a few. Similarly, the use of small wires as
discussed above may allow achieving a desired effective dielectric
constant and refractive index in small wire/polymer composites. The
suitable weight fraction of the small wires in such
polymer-comprising composites depends on the particular application
and desired properties, but typically ranges from around 0.01 wt. %
to around 95 wt. %.
[0084] In some applications, it may be advantageous to add a
particular color to otherwise transparent oxide small wire/polymer
composites. In some applications, suitable dyes or quantum dots may
be attached to the surface of the small wires or be infiltrated
into the pores (if present in the small wires). In some
applications, it may be advantageous to seal these pores in order
to prevent direct contact between the dyes (or quantum dots) and
surrounding environment. In some applications, the sealing material
may be a glass (e.g., oxide glass, etc.) or a ceramic or a
polymer.
[0085] A broad range of natural, semi-synthetic, and synthetic
polymers may benefit from the use of aluminum oxide small wires and
other ceramic as well as metal wires (particularly those described
herein). Structure-wise, these polymers may also be classified into
linear polymers, branched chain polymers, and cross-linked
polymers. These polymers may also be classified into various
thermoplastics, thermosets (or resins), elastomers (or rubbers),
and fibers (or natural polymers). Selected examples of suitable
thermoplastics include, but are not limited to, polyethylene (PE),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polypropylene (PP), polyvinyl chloride (PVC), polyether sulfone
(PES), polyetherether ketone (PEEK), polyetherimide (PEI),
polycarbonate (PC), various polyamides (e.g., nylon), various
polyesters (e.g., aliphatic polyester), acrylic (poly(methyl
methacrylate), PMMA), polytetrafluoroethylene (PTFE),
polybenzimidazole (PBI), polyacrylonitrile (PAN), polybuthadiene,
polystyrene (PS), polyoxymethylene (POM), and co-polymers of the
above polymers, among others. Selected examples of suitable
thermoset polymers include, but are not limited to, various alkyds
or polyester fiberglass polymers and polyester resins, various
amino (urea, melamine) polymers (including urea-formaldehyde,
phenol formaldehyde, melamine formaldehyde, etc.), various epoxy
resins (including those after esterification and other
modifications--e.g., vinyl ester), various phenolic resins
(bakelite or phenol-formaldehyde (PF)), various polyimides, various
silicones, various polyurethanes, polyisocyanurate (PIR), various
rubbers/elastomers (vulcanized rubber, neoprene, nitrile, styrene
butadiene, etc.), various heterocyclic compounds (e.g.,
polyhexahydrotriazine), and cyanate esters, to mention a few. Other
specific examples of other suitable polymers include, but are not
limited to, various (para-) aramid fibers, poly(vinyl alcohol)
(PVA), various proteins and polypeptides (including enzymes),
chitin (poly(N-acetylglucosamine)), silk (including spider silk)
and various polysaccharides (including starch, cellulose and
carboxymethyl cellulose, alginic acid and salts of alginic acid),
to name a few.
[0086] Suitable methods for the synthesis of composites comprising
aluminum oxide small wires (particularly those described herein,
including but not limited to porous aluminum oxide small wires) and
other ceramic small wires and metal small wires may include, but
are not limited to: various solution mixing techniques, solution
blending, melt blending, in-situ polymerization, solid-state shear
pulverization, and vacuum (e.g., resin) infusion, among others.
Solution blending involves dispersion of small wires in a suitable
solvent, mixing with a suitable polymer (at room temperature or an
elevated temperature), and recovering the composite by
precipitating or casting a film or a bulk sample or by other
suitable methods. A wet annealing method may be considered as a
variation of the solution blending--it involves partially drying a
small wire/polymer suspension on a substrate and then increasing
the temperature to above the glass transition temperature rapidly
to complete the drying process. Melt blending uses high temperature
and high shear forces to disperse small wires in a polymer matrix.
At high concentrations of small wires the viscosities of the
composites may be relatively high, which should be taken into
consideration (for some blending methods, too high of a viscosity
may reduce efficiency of uniform mixing). In-situ polymerization
involves dispersing small wires in a monomer followed by
polymerizing the monomers. It is noted that functionalization of
small wires may assist in improving the dispersion of the nanotubes
in a monomer (and similarly in a solvent for solution mixing and in
a polymer for melt blending). Strong covalent bonding may be formed
between small wires (particularly if they are functionalized) and
the polymer matrix (e.g., by using various condensation reactions).
For example, epoxy nanocomposites produced using in-situ
polymerization methods involving dispersion of small (optionally
functionalized) wires in a resin followed by curing the resin with
a hardener may allow formation of composites with a strongly
enhanced tensile modulus and other properties even with a small
mass fraction (e.g., less than 10 wt. %) of small oxide wires. In
some applications, the reactive agents may be first infiltrated
into the pores of the porous small wires before being subsequently
polymerized. In some applications, one may utilize reduced
temperatures to increase viscosity of the suspension to the level
when processing effectively proceeds in the solid state.
Solid-state mechano-chemical pulverization/mixing processes may be
used to mix small wires with polymers. Pulverization methods may be
used alone or followed by melt mixing. This may induce grafting of
the polymer on the surface of the small wires, which may result in
the improved dispersion, improved interfacial adhesion, improved
tensile modulus, improved hardness, and other positive improvements
in the mechanical properties of the small wire/polymer composites.
In another suitable method, small wires may be first processed into
dry porous membranes or porous solid bodies and laid into a
suitable mold. The polymer (resin) is then infiltrated (infused or
sucked) into the porous membranes/bodies comprising mold by
applying negative pressure (e.g., vacuum). Excess resin may be
removed out of the bodies by applying negative pressure (e.g.,
vacuum).
[0087] Small wire/polymer composite fibers may be produced by melt
fiber spinning, where the composite melt may be extruded through a
spinneret hole, and the extruded rod is air cooled and drawn under
tension by a windup spool to produce aligned composite fibers.
Electrospinning is yet another method to produce composite
(nano)fibers using electrostatic forces.
[0088] Examples of suitable uses of such small wire/polymer
composites include, but are not limited to, components of musical
instruments or whole musical instruments (for example, violin bows,
guitar pick-guards, drum shells, bagpipe chanters, cellos, violas,
violins, acoustic guitars, electric guitars, guitar picks,
ukuleles, etc.), bags and cases (for example, laptop cases,
backpacks, purses, etc.), cases, frames and components of various
electronic devices (for example, laptops, ultrabooks, tablets,
servers, printers, scanners, electronic books, monitors,
televisions, credit card terminals, cameras, microscopes,
spectroscopes and other research tools, monitors of various other
electronic devices or components of devices, etc.), audio
components (for example, turntables, loudspeakers, etc.), sporting
goods and sporting good components (for example, components of
bicycles, kite systems, etc.), various firearms use (for example,
to replace certain metal, wood, and fiberglass components, etc.),
components of automotive, aerospace and aircraft, ship, and other
transport devices (for example, components of cars, buses, planes,
ships and boats, spacecraft, drones, including rotor blades and
propellers, etc.), various legs, rods and poles (for example,
tripod legs, tent poles, fishing rods, billiards cues, walking
sticks, poles for high reach, such as the ones used by window
cleaners and water fed poles, posts that are used in restoring root
canal treated teeth, etc.), many other light and durable consumer
or military items (for example, handles of knives and tools,
various toys, cases for various devices, tents, etc.), clothes and
components of clothes (jackets, coats, shirts, pants and tights,
hats, gloves, masks, stockings, buttons, etc.), footwear and
components of footwear (boots, shoes, sandals, slippers, wides,
narrows, etc.), cases of watches and other wearable devices,
furniture, frames of reading glasses, components of various
appliances (ovens, stoves, blenders, grinders, vacuum cleaners,
refrigerators, dryers, washing machines, etc.), tableware, jewelry,
components of various protection equipment (safety screens,
helmets, personal protection equipment, etc.), furniture and design
components (chairs, mirrors, partitions, balustrades, tables,
shelves, lighting), electrical insulation materials, thermal
insulation materials, fire resistant materials, tires, and various
protective (for example, against corrosion or chemical attack)
coatings on metal or wood or ceramic parts, to provide a few
examples.
[0089] In some applications, the use of aluminum oxide (and other
oxide as well as other ceramic and metal) small wires (particularly
those described herein) in combination with carbon small wires
(carbon (nano)fibers or carbon nanotubes) or carbon platelets
(graphene, exfoliated graphite, etc.) may provide even more
advantages than using aluminum oxide (or other ceramic or metal)
small wires (or carbon small wires/platelets/tubes) alone in
various composites (such as ceramic composites, glass composites,
metal composites, polymer composites, carbon composites, etc.). The
utility may depend on the particular application and chemistry. For
example, in some cases, carbon may provide the needed electrical
conductivity to the composite, but may be hard to disperse
uniformly. The addition of aluminum oxide (or other ceramic small
wires) may assist in such a dispersion and additionally enhance the
strength of the composite. In other cases (applications), the
combination of oxide small wires and carbon may enhance thermal
stability (when compared to only using carbon), enhance catalytical
activity (when compared to either only carbon or only oxide),
enhance the modulus of toughness, etc. In yet another case, it may
be desirable to provide enhanced mechanical performance and
electrical connectivity within a composite with the smallest volume
fraction of small wires, but conductive carbon may undesirably
induce certain side reactions (e.g., as in battery electrodes).
Combining aluminum oxide (or other suitable ceramic) small wires
with carbon small wires (or carbon nanotubes, graphene, etc.) may
provide the desired mechanical property enhancement and sufficient
conductivity to the composite, while minimizing side reactions
induced by carbon.
[0090] In some applications, the use of aluminum oxide (and other
oxide and other ceramic and metal) small wires and other porous
materials (particularly those described herein, including but not
limited to porous aluminum oxide small wires and other porous
membranes and particles composed of ceramic or metal(s)) in various
types of solar cells (e.g., in perovskite solar cells, in organic
solar cells, tin sulfide solar cells, etc.) and light emitting
diodes (e.g., in organic LEDs, perovskite LEDs, various porous LEDs
including GaN-based ones, etc.) may be advantageous in terms of
improving their performance characteristics and long-term
stability. In some applications, catalyst-free formation of
organometallic compounds may be very advantageous for applications
in organic solar cells and organic light emitting diodes.
[0091] In some applications of the present disclosure, the use of
porous oxide (e.g., aluminum oxide) membranes (or porous ceramic
membranes or, in some cases, porous metal membranes), particularly
those produced according to the methods described herein (including
those comprising bonded small porous (as well as dense, essentially
pore-free) wires) as separation membranes may be advantageous. Such
membranes may offer excellent mechanical properties (high strength,
high toughness, high modulus, excellent creep and fatigue
resistance), excellent thermal stability, high permeability,
excellent chemical stability, high durability, lightweight, low
cost, high uniformity, good wetting by a broad range of liquid
materials, good flexibility, and many other attractive attributes.
Conventional aluminum oxide membranes are produced by anodization
of aluminum. This method suffers from long synthesis procedures and
very high cost, while the produced membranes are typically very
brittle, difficult to handle, and form cracks upon bending.
Furthermore, the pores in such membranes are typically straight
(see-through), which may be undesirable in some applications. In
addition, such conventional membranes are difficult to mass-produce
thinly (the minimum thickness is typically at least 50 microns). In
contrast, the suitable thickness of the disclosed membranes herein
may range from around 1 micron to around 20 mm for standalone
membranes and from around 100 nm to around 5 mm for membranes
deposited on another (e.g., porous) substrate. In some
applications, it may be advantageous for such membranes to
additionally comprise 0.1-90 wt. % polymer, 0.1-80 wt. % metal, or
0.1-80 wt. % carbon (e.g., for enhancing mechanical properties, for
enhancing separation properties, or for other functionality, such
as anti-bacterial, catalytic, etc., to name a few). Depending on
the particular application and membrane composition, the suitable
porosity in the disclosed membranes may range from around 0.001
vol. % up to around 99 vol. %. These separation membranes may be
utilized for various filtration applications separating various
particles (e.g., in the liquid or gaseous suspension state;
including, but not limited to, various soft matter (including
bio-related) particles, various ceramic particles, various carbon
particles, various composite particles, dust, etc., the size of
which may range from sub-mm to micron-scale and all the way up to
nanoparticles), separating various liquids and gases (particularly
if additionally comprising metals or polymers), among other
species. These membranes may also be utilized in various
applications requiring electrical insulation (e.g., in various
electrochemical and electrical devices, including energy storage
and energy harvesting devices, sensors, etc.). These membranes may
also be utilized in applications requiring air and water
filtration, including those where killing bacteria and bacteria
spores is important. For these applications, it may be advantageous
to deposit antibacterial (or anti-fungus) particles or coatings on
the inner (and/or outer) surface of the porous membranes. Copper,
its various alloys (e.g., brasses, bronzes, cupronickel,
copper-nickel-zinc, etc.) and its various complexes (including
those that comprise halogen atoms, such as Cl or Br), silver and
silver alloys and various silver complexes, various antifugal
complexes of Ni and Au, various organosilanes, various quaternary
ammonium compounds (including those covalently bonded to a membrane
surface or to a polymer layer on the membrane surfaces), and
antifungal peptides, among others, are illustrative examples of
materials suitable for use in such antibacterial or anti-fungus
particles and coatings. Titanium oxide coatings on the membrane
surface may also be used for catalytic decomposition of organic
matter. Similarly, formation and utilization of porous membranes
comprising copper, its various alloys (e.g., brasses, bronzes,
cupronickel, copper-nickel-zinc, etc.) and its various complexes
(including those that comprise halogen atoms, such as Cl or Br),
silver and silver alloys and various silver complexes, various
antifugal complexes of Ni and Au, titanium oxide and other suitable
compounds as main membrane constituent(s) (not just as surface
layer(s) or surface particles) may be advantageous.
[0092] The use of porous oxide (e.g., aluminum oxide) and other
suitable electrically isolative ceramic membranes, particularly
those produced according to the methods herein (including those
comprising bonded small porous (as well as dense, essentially
pore-free) wires), as separator membranes in electrochemical energy
storage applications (e.g., fuel cells, batteries, supercapacitors,
hybrid devices, etc.) may be particularly advantageous in view of
the growing importance of these applications and thus will be
described in more detail. The suitable thickness of such membranes
may range from around 0.1 microns to around 200 microns (typically
more desirable, from around 0.5 microns to around 100 microns).
Advantages of using small aluminum oxide wires as compared to
regular aluminum oxide particles include flexibility, strength, the
ability to achieve very high porosity (e.g., over 70%, which may be
important for high permeability), the ability to achieve a small
size of the pores (which may be important for the prevention of
potential Li dendrite penetration) and the ability to prepare thin
membranes. Advantages of using porous small wires as compared to
dense small wires include higher porosity (and thus higher
permeation) for the same wire packing density. In addition, porous
small wires may pack less densely compared with regular wires due
to their higher surface roughness and lower density, which further
increases separator permeation. Advantages of the described process
(e.g., versus casting of individual wires) include bonding between
individual wires, which helps to maintain robustness and resistance
to fracture of the separator (even if it is very thin), while
keeping it flexible. In some applications, it may be advantageous
for such membranes to additionally comprise 0.1-10 wt. % polymer or
0.01-10 wt. % of another ceramic (e.g., for enhancing mechanical
properties). Depending on the particular application, and membrane
composition, the suitable porosity in the disclosed membranes may
range from around 5 vol. % up to around 99.9 vol. % (more commonly
from around 30 vol. % to around 95 vol. %), where typically higher
porosity may be desired for thicker separator membranes or for
applications requiring faster ion transport. Such membranes in
energy storage applications may be infiltrated with a liquid or a
solid electrolyte when used in devices. Superior strength, puncture
resistance, outstanding thermal stability, low thermal expansion
coefficient, relatively high dielectric constant, low cost,
scalable manufacturability in thin form (down to 0.1 microns), good
wetting properties for a broad range of materials, stability
against reduction at low potentials (e.g., as low as 0 V vs. Li/Li'
in the case of aluminum oxide) and against oxidation at high
potentials (e.g., as high as 10 V vs. Li/Li.sup.+), resistance
against dendrite growth and other positive attributes of the
disclosed membranes make them particularly attractive in a broad
range of energy storage applications, including but not limited to
various metal ion (such as Li-ion, Na-ion, Mg-ion, etc.) based
energy storage devices (e.g., batteries including Li and Li-ion
batteries, Na and Na-ion batteries, Mg and Mg-ion batteries,
electrochemical capacitors, hybrid devices, etc.), to name a
few.
[0093] Conventional polymer separators for Li-ion batteries suffer
from limited mechanical strength and low thermal stability, which
may lead to thermal runaway and cell explosions. Formation of
flexible, strong, and thermally stable ceramic separators may
overcome serious limitations of polymer separators.
[0094] FIGS. 18A-18E, 19, and 20 show example aspects of the
fabrication and characterization of a flexible binder-free nonwoven
fabric separator composed of .gamma.-Al.sub.2O.sub.3 nanowires and
produced according to the process illustrated in FIG. 15, where
small Al ethoxide wires are first produced according to the process
illustrated in FIG. 13.
[0095] FIG. 18A compares results of simple wetting tests on a
commonly used commercial olefin (polypropylene, PP) separator
(top), a less common cellulose fiber (CF) separator (middle row),
and a nonwoven .gamma.-Al.sub.2O.sub.3 nanowire separator produced
in accordance with the techniques described herein (bottom row). In
this experiment, 5 .mu.L of a commonly used commercial electrolyte
(1M solution of LiPF.sub.6 in carbonates) was dropped onto the
separators and the wetted area was measured as a function of time.
Due to higher polarity (the presence of strong surface dipoles),
the wetting rate of the .gamma.-Al.sub.2O.sub.3 separator is
significantly higher, as determined by both the final wetting area
and the speed of wetting. Additionally, the uniformity of wetting
is increased because the as-produced .gamma.-Al.sub.2O.sub.3
nanowire nonwoven membrane material is non-directional. FIG. 18B
shows results of thermal stability tests performed starting at room
temperature and increasing to 800.degree. C. with separator samples
placed into the furnace for 2 minutes at each temperature. The
results effectively demonstrate the clear advantage of having a
flexible porous ceramic separator with operating temperatures in
excess of 800.degree. C. (which may be achieved in the case of cell
failure). In contrast, the most commonly used olefin separators
typically start melting at around 120.degree. C. and oxidize at
around 300.degree. C. Finally, the strength of ceramic fibers is
known to significantly exceed that of the olefins, which allows
formation of thinner separators in lithium ion batteries without
sacrifice of their mechanical properties. This, in turn, increases
cell energy density. For example, reduction in separator thickness
from 25 to 5 .mu.m leads to a 13-15% increase in cell energy
density, which typically translates into a similar reduction in
cell cost on the cost-per energy basis. FIGS. 18C, 18D, and 19 show
electrochemical performance of full cells with a graphite anode,
lithium iron phosphate (LFP) cathode, and all three types of
separators. While cells with all three types of separators
exhibited comparable performance at low (0.1C to 0.5C) current
densities, the cells with Al.sub.2O.sub.3 nanowire separators show
significantly higher capacities retained at high (1C to 5C)
discharge rates. The lack of detectable oxidation during cell
charging to 4.2 V shows the requisite chemical compatibility of the
Al.sub.2O.sub.3 nanowire separator. Noticeably smaller 2C
charge-discharge hysteresis may be observed in cells with
Al.sub.2O.sub.3 nanowire separator, which can be advantageous for
various applications. Such a difference in hysteresis suggests
better transport properties and lower cell polarization provided by
the Al.sub.2O.sub.3 nanowire separator. FIG. 18E shows results of
independent electrochemical impedance spectroscopy (EIS) testing of
these three separators using symmetric coin cells with stainless
steel working and counter electrodes. They showed a consistently
higher conductivity of Al.sub.2O.sub.3 nanowire separators, thus
demonstrating their additional advantage in battery
applications.
[0096] FIG. 20 shows results of a numerical analysis of the changes
in the electrolyte wetted area of the three separators from FIG.
18A. Faster wetting of the ceramic (e.g., Al.sub.2O.sub.3)
separators may be advantageous in applications that benefit from
reduced cell polarization and faster charge or discharge rate
performance.
[0097] Overall, the use of extra-thin (e.g., less than 5-10 .mu.m)
and highly porous (e.g., porosity greater than 75%) aluminum oxide
(and other suitable oxide and suitable ceramic) membranes may allow
one to noticeably increase the rate capability and energy density
of Li and Li-ion batteries as well as that of other batteries,
while increasing or maintaining the required level of safety. This
level of porosity, beneficial for high rate capabilities, in
combination with mechanical integrity and flexibility is only
attainable using small wire-like structures because regular (e.g.,
near spherical) particle-based ceramic structures require
substantially denser packing to produce a mechanical network and
are typically not very flexible. By moving away from the typical
use of polymers in the Li-ion battery separator, the thinner (e.g.,
to around 5 .mu.m) ceramic separators (such as those described
herein) will demonstrate higher strength and fracture toughness
than thicker (e.g., a 20 .mu.m thick) polymer separator with
ceramic coating(s), while also reducing the thickness of the
Anode/Separator/Cathode stack by approximately 10%, thereby
increasing the energy density of the Li-ion battery by 10%--a major
benefit. Increased cell energy density will also reduce the system
costs ($/kWh) of battery packs as, for example, 10% fewer cells may
be packaged and monitored for the same capacity. Due to their high
stability at high potentials, such membranes may be used in
combination with high voltage cathodes (e.g., cathodes having an
average lithiation potential from around 3.9 to around 5.6 V vs.
Li/Li.sup.+) in Li and Li-ion battery cells. It is noted that in
addition to using a standalone porous aluminum oxide membrane,
small wires (e.g., made of aluminum oxide or porous aluminum oxide)
may be directly deposited on at least one of the electrodes by
using casting or spray deposition or by field-assisted deposition
or dip coating, or another suitable method. Such deposited wires
may serve as an integrated (thin and flexible) membrane separating
anodes and cathodes from direct electrical contact, while providing
small resistance to ion transport and occupying a relatively small
space.
[0098] In addition to Al.sub.2O.sub.3 membranes, other ceramic
membranes (including those produced from or comprising small wires,
including porous small wires) may be utilized as separators in
Li-ion and other batteries. These include MgO, ZrO.sub.2, and many
others. The important parameters are mechanical properties,
stability of the ceramic membrane in electrolyte and (in case of
direct contact with positive or negative electrodes) the lack of
electrochemical side reactions (such as significant lithiation or
dissolution, in contact with electrodes).
[0099] In some applications, it may be advantageous to deposit a
porous polymer layer on one or both sides of the ceramic
(Al.sub.2O.sub.3, MgO, ZrO.sub.2, WO.sub.2, W.sub.2O.sub.3, etc.)
separator membrane in order to further reduce small side reactions
with electrodes. For example, when such membranes are used in Li or
Li-ion (or Na or Na-ion or other metal or metal-ion) batteries,
depositing such a porous polymer layer (e.g., porous ethylene,
porous propylene, porous aramid, porous cellulose, etc.) on the
anode side of the membrane may prevent undesirable side reactions
(e.g., lithiation, reduction, etc.) between the anode and the
ceramic separator. Similarly, formation of such a porous polymer
layer on the cathode side of the membrane may reduce potential
undesirable oxidation reactions. A suitable thickness of such a
porous polymer layer may range from around 10 nm to around 10
microns. In some applications of Li and Li-ion (or other metal or
metal-ion batteries), it may be advantageous to deposit a thin
(e.g., from about 1 nm to about 200 nm), mostly nonporous (dense)
polymer layer on the inner surface of the membrane (e.g., around
individual or bonded wires) to prevent direct Li contact with the
ceramic wires (e.g., in case of Li dendrite formation). It may be
further preferable for such a polymer layer to be stable in contact
with Li and exhibit high interfacial energy at the polymer/Li
interface. In this case, formation of the Li dendrite would result
in a substantial increase in the energy of the system and its
growth may be significantly reduced or eliminated. In contrast,
direct contact of Li with many ceramic materials may result in the
formation of a low-energy interface, which would reduce the surface
energy of the Li dendrite and thus undesirably favor its
propagation.
[0100] In some applications, it may be advantageous for the porous
polymer layer on one or both sides of the ceramic (Al.sub.2O.sub.3,
MgO, ZrO.sub.2, WO.sub.2, W.sub.2O.sub.3, etc.) membrane to be
thermally responsive (or comprise a thermally responsive layer) and
close pores above a certain temperature. This may provide an
additional safety feature of the cell because above a certain
temperature (e.g., selected in the range from about 70 to about
150.degree. C., for typical applications; for some applications,
above 100.degree. C.) the membrane would shut the current flow. In
some designs, a thermally responsive layer may comprise a
thermoplastic that melts above a critical temperature (e.g.,
selected in the range from about 70 to about 150.degree. C., for
typical applications) to cut off Li ion conduction.
[0101] In some applications, the use of oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, etc.) or other suitable
ceramic small wire (including but not limited to porous small
wires) membranes (particularly in combination with the
above-discussed polymer coatings) in metal anode-based battery
cells in medium sized (from around 10 mAh to around 200 mAh), large
(from around 200 mAh to around 10,000 mAh), or extra-large (above
around 10,000 mAh) cells may be particularly advantageous. Example
of suitable metal anode-based battery cells include, but are not
limited to, cells with a Li anode (e.g., as in Li metal batteries),
Mg anode (e.g., as in Mg metal batteries), Na anode (e.g., as in Li
metal batteries), Zn anode (many battery chemistries comprising Zn
or Zn alloy anodes and electrolytes that do not induce dissolution
or reduction of small wire membranes), and K anode (e.g., as in K
metal batteries), to name a few. Rechargeable metal anode batteries
may particularly benefit from this membrane technology. Metal
anodes in such rechargeable battery cells typically undergo metal
stripping (dissolution into electrolyte as ions) during discharging
and re-plating during charging. This process typically leads to the
formation of dendrites that may induce internal shorting, which may
lead to battery failure (and, in some cases, to various safety
risks such as fires, particularly known in Li battery chemistries).
The use of solid electrolytes or surface layer protection with a
solid ceramic protective layer is often expensive, not always
feasible, and does not always protect the cell from dendrite
penetration (particularly in situations where the battery may be
shocked or exposed to various stresses, as when used in
transportation). While it is common in battery research for
scientists to utilize so-called half cells with metal anodes (e.g.,
Li half cells) in order to evaluate the performance of their
electrode materials or separators (typically in very small coin
cells having a capacity below 10 mAh), the use of metal anodes in
commercial cells (particularly in rechargeable cells with liquid
aqueous and organic electrolytes) is rare because of their higher
cost as well as reliability and safety concerns (larger sized cells
would release more energy during dendrite-induced thermal runaway
and rapid disassembling, particularly when flammable organic
electrolytes are utilized). The use of small wire membranes as
described herein (e.g., porous aluminum oxide, magnesium oxide, or
zirconium oxide membranes, to provide a few examples) with a
relatively high elastic modulus of the membrane material, high
porosity, and (potentially importantly) small (e.g., below 2
microns, more preferably below 0.25 microns, on average) and
tortuous pores may greatly suppress or eliminate dendrite growth,
while providing relatively fast metal (e.g., Li, Mg, Zn, etc.)
deposition (plating) and thus high power density. While a detailed
understanding of this phenomena is still lacking, it may be related
to the associated increase in surface area (and thus surface
energy) of a dendrite, which leads to a high energy barrier for
dendrite formation, particularly if the individual wires are coated
with a suitable polymer layer (e.g., a polymer that is stable in
direct contact with a metal anode, exhibits high elastic modulus
and exhibits high interfacial energy in such a contact). While
metal dendrites may penetrate through many polymer membranes
(during metal dendrite growth in a cell with a polymer separator
membrane), the metals dendrites are typically too soft to penetrate
through individual small oxide wires (e.g., small aluminum oxide
wires) even if these are coated with polymer layers. Therefore,
metal dendrite formation may require dendrites to grow around the
small wires (within small and tortuous pores formed between the
small wires in a membrane), which significantly increases the
dendrite specific surface area. The small features of the membrane
walls, its roughness, its dielectric properties, or its surface
properties may also be responsible for the suppression of dendrite
growth.
[0102] In some applications, the use of oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, etc.) and other suitable
ceramic small wires (including but not limited to porous small
wires) membranes in battery cells comprising so-called
"conversion"-type (including so-called "chemical
transformation"-type) electrode materials (particularly in medium
sized, from around 10 mAh to around 200 mAh), large (from around
200 mAh to around 10,000 mAh) or extra-large (above around 10,000
mAh) cells) may be particularly advantageous. In contrast to
so-called "intercalation" electrodes, conversion materials break
and create new chemical bonds during insertion and extraction of
ions (e.g., Li ions in the case of Li-ion and Li-metal batteries).
Two types of conversion reactions may be distinguished for Li
chemistries:
Type A (true conversion): M'X.sub.z+y LiM+z Li.sub.(y/z)X (Eq.
1)
Type B (chemical transformation): yLi+X'Li.sub.yX, (Eq. 2) [0103]
where M'=cation, M=reduced cation material, and X'=anion.
[0104] For the type A cathodes, M' are typically transition metal
ions, such as Fe.sup.3+, Fe.sup.2+, Ni.sup.2+, Cu.sup.2+,
Co.sup.2+, Bi.sup.2+, Ag.sup.+, Mn.sup.3+, etc., while X' are
typically halogen ions (such as F.sup.-, Cl.sup.-, Br.sup.-, and
I.sup.-) or chalcogenide ions (such as S.sup.2-, Se.sup.2-, etc.).
X' may also be O.sup.2-. Suitable examples of "conversion"-type
active electrode materials include, but are not limited to, various
metal halides and oxi-halides, various chalcogenides (including,
but not limited to, Li.sub.2S and S), various metal oxides, various
metal hydroxides and oxyhydroxides, their mixtures and alloys, etc.
During operation of rechargeable cells, conversion-type electrodes
typically exhibit some undesirable interactions with electrolytes.
For example, liquid electrolytes may induce dissolution or etching
of such electrode materials (the dissolution of lithium
polysulfides in lithium-sulfur cells is particularly well-known;
the dissolution of metal components of the conversion-type
electrodes is another example). In addition to the loss of active
material in the electrode (e.g., in a cathode), the components of
the dissolved species may travel to an opposite electrode (e.g., to
an anode) and induce undesirable damage to its surface (e.g.,
damage to the anode solid electrolyte interphase) or at least
partially block ionic pathways to the anode, leading to an
undesirable increase in resistance and reduction of capacity of a
cell. The use of the above-described small wire membrane may
alleviate such negative effects by adsorbing dissolved species on
its surface or by adsorbing harmful electrolyte components (e.g.,
fluorine and fluorine-containing ions, various halogen and
halogen-containing ions, H.sub.2O, etc.) on its surface or by other
mechanisms. High specific surface area resulting from the small
diameter of the small wires may be advantageous for maximizing its
positive impact.
[0105] In some applications, the use of oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, etc.) and other suitable
ceramic small wires (including but not limited to porous small
wires) membranes in metal and metal-ion (e.g., in Li and Li-ion)
battery cells comprising so-called "alloying" active materials
(e.g., Si, Sn, P, Al, Ge, Sb, Bi, etc.) may be advantageous. The
inventors have found that the presence of traces of water,
hydro-halide (e.g., HF) acid, fluorine ions, and other
halide-comprising ions in liquid organic electrolytes may induce
undesirable damage to the surface of such materials (particularly
strong damage to Si, Sn, and Ge) during cell operation. The use of
the above-described small wire membrane may alleviate such negative
effects by adsorbing harmful electrolyte components (e.g., fluorine
and fluorine-containing ions, various halogen and
halogen-containing ions, H.sub.2O, etc.) on its surface or by other
mechanisms. High specific surface area resulting from the small
diameter of the small wires may be advantageous for maximizing its
positive impact. In addition, stresses and additional heat
originating from the volume changes in "alloying" or "conversion"
active materials during cycling may induce damage in polymer
separators. The use of more robust ceramic separators instead of
traditional polymer separators may thus be advantageous in terms of
cell stability and performance.
[0106] In some applications, the use of oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, tungsten oxide, tantalum
oxide, etc.) and other suitable ceramic small wires (including but
not limited to porous small wires) membranes in metal and metal-ion
(e.g., in Li and Li-ion) battery cells comprising high voltage
cathode materials (e.g., materials with average Li extraction
potential in the range from around 3.8 V to around 5.8 V vs. Li/Li'
or cathode materials with a maximum charge potential from around
4.4 V to around 6.2 V vs. Li/Li.sup.+). At elevated potentials
(typically above around 3.8-4.3 V vs. Li/Li.sup.+) such a cathode
may exhibit some undesirable interactions with electrolytes, such
as, for example, dissolution or etching of metal components (e.g.,
Mn, Co, Ni, etc.) of such cathodes. Such reactions may be
particularly harmful if traces of hydro-halide (e.g., HF) acid,
fluorine ions, and other halide-comprising ions are present in
liquid electrolyte. The use of the above-described small wire
membrane may elevate such negative effects by adsorbing harmful
electrolyte components (e.g., fluorine and fluorine-containing
ions, various halogen and halogen-containing ions, etc.) on its
surface or by other mechanisms. High specific surface area
resulting from the small diameter of the small wires may be
advantageous for maximizing its positive impact.
[0107] In some applications, the use of an ionically permeable
(e.g., porous) polymer layer between the oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, etc.) small wires
(including but not limited to porous small wires) membranes and at
least one of the electrodes may be beneficial for their use as
separators in electrochemical cells (e.g., battery cells). Such a
polymer layer may be deposited on a membrane or on an electrode or
simply sandwiched between the ceramic membrane and at least one of
the electrodes. Such a polymer layer may serve different useful
functions. In one example, it may reduce stress concentration at
the interface between an electrode and the porous oxide separator
(because polymers are typically softer and more deformable compared
to oxides). This may lead to enhanced reliability during cell
assembling when the cell stack is pressurized and to a more
reliable cell operation. In another example, such a polymer layer
may make the oxide separator easier to handle (e.g., during cell
assembling or oxide membrane production). In yet another example,
such a polymer layer may enhance adhesion between the oxide
membrane and an electrode (e.g., essentially serving as a
gluing/adhesive layer). In yet another example, such a polymer
layer may enhance electrochemical stability of the oxide membrane.
As described above, for example, in the case of Li or Li-ion
batteries the use of a polymer layer between an oxide membrane and
an anode may prevent reduction of the oxide by Li or other
unfavorable interactions at low potentials (e.g., below around
0.1-2 V vs. Li/Li.sup.+, depending on an oxide and electrolyte
chemistry). In this case, not only aluminum, magnesium, and
zirconium oxides, but also many other oxides that are typically
unstable or significantly less table in contact with Li may be
utilized (e.g., silicon oxides, zinc oxides, iron oxides, magnesium
oxides, cadmium oxides, copper oxides, chromium oxides, titanium
oxide, various combination of oxides, etc.). If a polymer layer is
placed between an oxide membrane and a cathode, it may prevent or
minimize various undesirable interactions between an oxide and
electrolyte or a cathode at higher potentials (e.g., above around
3-4 V vs. Li/Li.sup.+, depending on the oxide and electrolyte
chemistry). In yet another example, such a polymer layer may serve
as an additional safety mechanism. For example, it may prevent ion
transport (e.g., by closing the pores or by becoming impermeable by
the electrolyte solvent, or by other mechanisms) if heated above a
critical temperature (or cooled below a critical temperature). The
suitable porosity of such a polymer layer may range from around 0
to around 99 vol. % (more preferably, from around 10 to around 90
vol. %). The suitable thickness of such a polymer layer may range
from around 5 nm to around 20 microns (more preferably, from around
10 nm to around 10 microns). Thicknesses smaller than around 5 nm
may typically reduce the usefulness of such a polymer layer, while
thickness larger than around 20 microns undesirably increase the
total separator stack thickness and may also induce harmful effects
(e.g., polymer shrinking during heating may also damage an oxide
membrane). The polymer layer may be a part of a multi-layer (oxide
wire-comprising) membrane or be deposited on at least one of the
electrodes or be prepared as a stand-alone film. The composition of
the polymer layer may depend on a particular functionality that is
desirable and a particular chemistry of an electrochemical cell,
and may be selected from the list of polymer compositions discussed
in conjunction with the polymer composites described herein.
[0108] In some applications, the use of oxide (e.g., aluminum
oxide, magnesium oxide, zirconium oxide, etc.) or other suitable
ceramic small wires (including but not limited to porous small
wires) as thermally stable, electrically isolative mechanical
reinforcement in electrodes, solid (e.g., polymer, ceramic,
glass-ceramic, or composite) electrolyte and separators of various
batteries (e.g., Li and Li-ion batteries, Na and Na-ion batteries,
etc.) and other electrochemical energy storage devices may also be
highly advantageous. Small wires may enhance mechanical strength,
fatigue resistance, and overall durability of the electrodes
without providing undesirable electrochemically active surface area
for decomposition of electrolyte due to the lack of electrical
conductivity in aluminum oxide and other oxides, in contrast to,
for example, carbon nanotubes or carbon fibers and nanofibers. In
addition, the use of oxide (e.g., aluminum oxide, magnesium oxide,
etc.) or other suitable ceramic small wires may be advantageous for
providing (and maintaining during cycling) fast ionic pathways
within electrodes. For example, pores in the porous oxide (e.g.,
aluminum oxide or magnesium oxide, etc.) small wires may be
utilized as pathways for ion access from the top surface to the
bulk of the electrode. Since these pores may remain filled with
electrolyte but empty from electrolyte decomposition products and
since mechanical strength of the oxide may be sufficiently large to
withstand volume changes in the electrodes during operation without
inducing collapse of the pores, such pores may be successfully
utilized for maintaining high ionic conductivity within the
electrode during cycling. In some applications, the use of oxide
(e.g., aluminum oxide or magnesium oxide) small wires (including
but not limited to porous small wires) in combination with carbon
nanotubes, carbon fibers (nanofibers), carbon small wires, and
other carbon particles may be advantageous. The oxide wires may
help to disperse binder and/or carbon particles within the
electrode and enhance mechanical stability of the electrodes
(particularly important for electrodes comprising high capacity
(e.g., greater than about 400 mAh/g in the case of anodes and
greater than about 250 mAh/g in the case of cathodes) or high
volume changing (e.g., greater than about 10 vol. %) active
materials), while conductive carbon may enhance electrical
connectivity between individual electrode particles comprising
active materials.
[0109] In some applications, the use of the various small wire
comprising composites (particularly those described herein) in the
form of fibers, nanofibers, threads, ropes, and fabrics may be
advantageous. Such fibers may be produced, for example, by
spinning, melt-spinning or electrospinning, extrusion or other
suitable methods of composite fiber fabrications.
[0110] In some applications, the use of small oxide (e.g., aluminum
oxide, magnesium oxide, or other oxide) and ceramic wires and oxide
(e.g., aluminum oxide or other oxide) and ceramic membranes,
particularly those produced according to the methods herein, in
small wire/ceramic composites is advantageous.
[0111] In some applications, the use of metal (such as aluminum,
magnesium, titanium, etc.) oxyhydroxides, hydroxides, and oxides in
the form of small wires (particularly those described herein,
including porous small wires) or in the form of porous membranes as
fillers in asphalts and concretes (including asphalt concretes) may
be advantageous in terms of increasing strength, toughness, fatigue
resistance, improving dynamic modulus, moisture susceptibility,
creep compliance, rutting resistance and freeze-thaw resistance,
reducing manufacturing time and energy consumption, and providing
other benefits compared to the use of regular (small wire-free)
asphalt, brick (and other masonry structures), or concrete
compositions. Furthermore, the application of such small wires may
provide better durability and properties when compared to more
traditional fiber-reinforced concretes with typical polypropylene
fibers, polyester fibers, asbestos fibers, cellulose fibers, carbon
fibers, glass fibers, and nylon fibers. In some applications, it
may be advantageous to use metal (such as aluminum, magnesium,
titanium, and other metal) oxyhydroxides, hydroxides, and oxides in
the form of small wires (particularly those described herein,
including porous small wires) or in the form of porous membranes in
combination with polymer (e.g., polypropylene, polyester,
cellulose, nylon), mineral (e.g., asbestos), carbon, or glass
fibers. The suitable mass fraction of small wires in asphalts and
concretes may range from around 0.001 wt. % to around 40 wt. %. In
some applications, it may be advantageous to use small wire/polymer
composites or porous membranes/polymer composites (such as
aluminum) oxide/polymer composites, particularly those described
herein, including porous small wires) (for example, in the form of
fibers, timber structures, rods, etc.) as reinforcements in
structural applications (such as concretes, asphalts, buildings,
etc.).
[0112] In some applications, the use of aluminum oxide (and other
oxide) and other ceramic (e.g., carbide) small wires (particularly
those described herein) as fillers in various metals and metallic
alloys may be highly advantageous in terms of increasing hardness,
strength (and specific strength), fatigue resistance, elastic
modulus, wear resistance, scratch resistance, thermal stability,
creep resistance, fracture toughness, manufacturability in thin
foil states, and other important properties of metals and metal
alloys. The applications of such small wire/metal composites may
include cases for a broad range of devices, sporting goods, various
medical tools, various cutting tools (including cutting blades),
various components of electronic devices, various conductive small
wires, jewelry, various components of transportation devices
(including but not limited to land, sea, and air and space
transportation), various constructions and load-bearing
applications, various energy storage devices, various protection
devices, and various engines and turbines, to name a few. Examples
of suitable lightweight metals and metal alloys include, but are
not limited to, aluminum and various aluminum alloys, magnesium and
various magnesium alloys, titanium and various titanium alloys, and
beryllium and various beryllium alloys. Examples of suitable
structural (including piping, plumbing, gearing, valves, engines,
turbines, etc.) metals and metal alloys include, but are not
limited to, iron and iron alloys (e.g., various steels, including
carbon steel and stainless steel, among others), copper and copper
alloys, aluminum and aluminum alloys, magnesium and various
magnesium alloys, zinc and zinc alloys (e.g., for soldering or
surface coatings), tin and tin alloys (e.g., for soldering), lead
and lead alloys (e.g., for soldering), vanadium and vanadium alloys
(mostly as components of other alloys), chromium and chromium
alloys (mostly as components of other alloys), tungsten and
tungsten alloys (e.g., in armor, in gas turbines, etc.), and nickel
and nickel alloys. Examples of suitable metal and metal alloys for
use in current collectors and conductive small wires and other
applications requiring high electrical conductivity include, but
are not limited to, gold and gold alloys, silver and silver alloys,
aluminum and aluminum alloys, copper and copper alloys, platinum
and platinum alloys, molybdenum and molybdenum alloys, zinc and
zinc alloys, lithium and lithium alloys, tungsten and tungsten
alloys, brass, nickel and nickel alloys, titanium and titanium
alloys, and palladium and palladium alloys, to name a few. Examples
of suitable metal and metal alloys for use in jewelry and
jewelry-related (e.g., watches and portable and wearable electronic
devices) applications include, but are not limited to, gold and
gold alloys (e.g., 10 karat, 12 karat, 14 karat, 18 karat, 22
karat, 24 karat, etc., various types of white gold and rose gold
alloys, etc.), platinum and platinum alloys, silver and silver
alloys, various nickel alloys (e.g., so-called "nickel-silver,"
which comprises Ni, Cu, and Zn), palladium and palladium alloys,
rhodium and rhodium alloys, tungsten and tungsten alloys, titanium
and titanium alloys, various stainless steels, and copper and
copper alloys (including brass), to name a few. Examples of
suitable high temperature corrosion resistant alloys include, but
are not limited to, various nickel-based super-alloys, molybdenum
alloys, tungsten and tungsten alloys, stainless steels, and
tantalum alloys and titanium alloys, to name a few examples.
Examples of other suitable metal and metal alloys include, but are
not limited to, metals and alloys comprising at least one of the
following elements: Cr, Mn, Co, Y, Zr, Nb, Mo, Tc, Ru, Rh, Pd, Cd,
In, Ga, Sn, Hf, Ta, Re, Os, Ir, Hg, Rf, Db, Sg, Bh, Hs, Mt, La and
various elements in the lanthanide series, Ac and various elements
in the actinide series, and various shape memory alloys, to name a
few. The suitable mass fraction of small wires in metal-wire
composites may range from around 0.002 wt. % to around 85 wt.
%.
[0113] In some applications, it may be advantageous to add a
particular color to oxide small wire/metal composites to modify the
otherwise "regular metallic" color. For example, it may be
advantageous for "colored" (e.g., black, white, blue, red, green,
velvet, yellow, gold, silver, or other color) cases and frames of
various electronic devices (laptops, ultrabooks, tablets,
electronic books, televisions, credit card terminals, cameras,
microscopes, spectroscopes and other research tools, monitors of
various other electronic devices or components of devices, etc.),
cases of watches and other wearable devices, furniture, frames of
reading glasses, components of automotive, aerospace, ship and
other transport devices (cars, buses, planes, ships, spacecraft,
drones, etc.), components of various appliances (oven doors, cook
tops, etc.), tableware glass, jewelry, components of various
protection equipment (safety screens, helmets, personal protection
equipment, etc.), various sporting goods, various interior design
and furniture (mirrors, partitions, balustrades, tables, shelves,
lighting) and other devices where it is desirable to not reveal
scratches. It may be desirable for the metals and small wire/metal
composites to exhibit a uniform color throughout the metal (small
wire/metal, porous oxide-metal) part(s) or at least through a
sufficiently thick surface layer (typically at least 1 micron or
more, preferably 10 microns or more) instead of introducing it to a
thin layer on the surface (e.g., by anodization) or using a
relatively soft polymer-based paint on the surface. Conventionally,
various dyes are difficult to introduce (without damage to the
dyes) and distribute uniformly within a metal (particularly without
reducing metal mechanical properties). The present disclosure
overcomes this limitation. For example, in some applications,
suitable dyes or quantum dots may be attached to the surface of the
oxide small wires or be infiltrated into the pores (if present in
small wires) prior to the formation of the small wire/metal
composites. In some applications, it may be advantageous to seal
these pores in order to prevent direct contact between the dyes (or
quantum dots) and metal. In some applications, the sealing material
may be a glass (e.g., oxide) or a ceramic (e.g., an oxide, a
nitride, or a carbide, to provide a few examples). In some
applications, porous oxides of not elongated shape (not small
wires) and other porous materials may be utilized for the purpose
of introducing a color to a metal or metal-ceramic composite. In
some applications, instead of dyes, particles or coatings may be
utilized (e.g., carbon particles or carbon coating for "black"
color).
[0114] Examples of suitable methods for the formation of small wire
(e.g., aluminum oxide small wire, among other oxides and other
ceramic small wire)/metal composites include, but are not limited
to, plating and electroplating (e.g., through small wire-comprising
or small wire-based membranes or small wire-based porous bulk
samples), melt-infiltration (e.g., into small wire-comprising or
small wire-based membranes or small wire-based porous bulk
samples), physical vapor deposition (sputtering, pulse-laser
deposition, etc.), chemical vapor deposition, various mechanical
alloying methods (e.g., ball milling, friction stir, etc.), various
powder metallurgy methods (including, but not limited to, various
sintering methods, such as spark plasma and plasma-activated
sintering and magnetic-field-assisted sintering, pulsed current hot
pressing, hot isostatic pressing, hot pressing, etc.), various
casting methods (e.g., pressure casting, hot pressing including
vacuum hot pressing, squeeze casting, etc.), sheath rolling, and
ultrasonic consolidation, to name a few. As mentioned above, in
order to tune the small wire/metal interface strength, in order to
improve wetting of metals on the small wire surface, or in order to
tune other properties of the small wire/metal interface (or
interphase), it may be advantageous to pre-coat the small wire
surface with coatings of other materials (e.g., by carbon, by
ceramic--e.g., carbides (such as boron carbide, aluminum carbon,
etc.) or by metals (e.g., by metals other than the "main" metal of
the small wire-metal composites)).
[0115] In some applications, it may be advantageous to utilize some
of the above-described lightweight small wire (e.g., aluminum oxide
small wire, among other oxides and other ceramic small wire)/metal
composites in ballistic protection applications (e.g., in
bulletproof or stab-protective wests or bulletproof structural
materials, such as plates, etc.). Lightweight alloys (such as
aluminum alloys, magnesium alloys, titanium alloys, beryllium
alloys, their combinations, etc.) and (in the case of plates) steel
may be particularly advantageous for use in such composites. As
mentioned above, it may be advantageous to pre-coat the small wire
surface with coatings of other materials (e.g., by carbides (such
as boron carbide, silicon carbide, aluminum carbon, among others),
borides, etc.), by metals (e.g., by metals other than the "main"
metal of the small wire/metal composites), or by polymers) in order
to optimize mechanical properties of the small wire/metal
composites and improve wetting of metals on the small wire surface.
In some ballistic applications, polymers may be used instead of
metals in such composites. Examples of suitable polymers include,
but are not limited to, nylon, polyethylene, polyacrylonitrile
(PAN), aramids (such as p-phenylene terephthalamides (PPTA)),
polybenzoxazole, poly(pyridobisimidazole) (such as commercially
available Kevlar.RTM. (e.g., Kevlar 49, 149, etc.), Zylon.RTM. HM,
M5.RTM. (PIPD), Twaron.RTM., Technora.RTM., Zylon.RTM., etc), silk,
spider silk, among others. In some ballistic applications, ceramic,
carbon, and glass may be used instead of metals in such composites.
In some applications, the small wire-comprising composites may be
in the form of fibers or fabrics. In some ballistic applications,
silicon carbide, boron carbide, or carbon small wires or platelets
(or plates) as well as aluminum oxide platelets (or plates) may be
utilized in addition to aluminum oxide small wires in such
composites. The suitable mass and volume fractions of the small
wires in ballistic protection composites may range from around 0.01
vol. % (and around 0.01 wt. %) to around 80 vol. % (and around 80
wt. %).
[0116] In some applications, the use of aluminum oxide (or other
oxides and other ceramic) small wires (particularly those described
herein) or porous bodies or porous membranes in catalyst
applications may be advantageous. The use of oxide or ceramic small
wires in combination with carbon particles (such as carbon
nanotubes, exfoliated graphite, graphene, porous carbon particles,
carbon nanoparticles, etc.) or carbon coatings may be
advantageous.
[0117] In some applications, it may advantageous to use aluminum
oxide (and other oxide as well as other suitable ceramic) small
wires (particularly those described herein) or porous bodies or
porous membranes as substrates for catalysts utilized for the
photodegradation of toxic organic pollutants. Benefiting from the
high surface area, good dispersion, and chemical stability of these
oxide small wires, the catalysts (e.g., TiO.sub.2, ZnO,
Bi.sub.2O.sub.3, BiVO.sub.4, etc.) may exhibit high and stable
photocatalytic activity for the degradation and mineralization of
various toxic organic pollutants. Good mechanical stability,
thermal stability, high porosity, and high permeability of the
small oxide wires-based porous substrates (e.g., membranes) make
them particularly attractive for such applications.
[0118] In some applications, some or all of the pores in the porous
ceramic (e.g., oxide) small wires may be infiltrated with
functional fillers for improved performance in various
applications. Examples of useful functional fillers may include:
(i) magnetic (e.g., ferrimagentic materials, ferromagnetic
materials, etc.) materials, (ii) superconductive materials, (iii)
piezoelectric materials, (iv) ferroelectric materials (including
pyroelectric materials), (v) various other markers or sensing
materials (detectors), (vi) various optical materials, (vii) strong
dielectrics, and others. Magnetic fillers may be used to orient the
small wires along the desired direction by application of a
magnetic field (which may be advantageous, e.g., in making improved
composites or during the operation of the materials or devices, or
both). Magnetic fillers may make it easier to assemble cells with
ceramic small wire-based separators. Porous wires filled with
magnetic materials and thus attaining magnetic properties may be
used as soft or hard magnets (depending on the filler) and be used
in corresponding applications (e.g., transformers, inductors,
electric machines, electomagnet cores, relays, magnetic recording
heads, magnetic amplifiers, filters, etc., for soft magnets or
magnetic recording (storage) media, permanent magnets (e.g.,
integrated in multifunctional materials), loudspeakers and
headphones, phone receivers, starter motors, servo motors, stepper
and other motors, MRI scanners, etc. for hard magnets).
Superconductive materials (e.g., filled within interconnected pores
of the, e.g., small oxide wires or other ceramic wires or metal
organic wires or metallic wires) may allow these to attain
superconductive properties (e.g., below a critical temperature or
below a critical magnetic field) and used in functional (or
multifunctional) devices. Confinement of the superconductive
materials within the (nano)pores of the small wires may provide
additional performance (or stability) advantages and improve the
mechanical (or other) properties of the superconductors. The
produced filled porous wire composites may be parts of other
materials or devices. Piezoelectric fillers may make the wires
attain piezoelectric properties. Porous wires filled with
piezoelectric materials and thus attaining piezoelectric properties
may also be used, e.g., in piezoelectric transducers, crystal
oscillators, delay lines, filters, accelerometers, earphones,
speakers, microphones, and spark generators, to name a few. The
confinement of the piezoelectric materials into the pores (e.g.,
interconnected pores) of the wires may enhance their performance or
stability, or allow formation of 1D (wire-shaped) piezoelectric
materials or 2D (membrane-shaped) ferroelectric materials, or may
allow attaining multifunctional properties. Ferroelectric fillers
may make the wires attain ferroelectric properties. These
properties may help to orient the wires along the desired
direction(s) by applying an electric field (which may be
advantageous, e.g., in making improved composites or during the
operation of the materials or devices, or both). Porous wires
filled with ferroelectric materials and thus attaining
ferroelectric properties may also be used, e.g., in electronic
circuits, electro-optic modulators, high-k-dielectrics, capacitors
(e.g., with tunable or non-tunable capacitance), ferroelectric
random access memory, ferroelectric tunnel junction devices,
sensors, multiferroics, fire (or heat) sensors, sonar, vibration
sensors, fuel injectors, etc. Pyroelectric fillers is a sub-class
of the ferroelectric fillers, in which the dipole moment depends on
temperature. These are particularly useful as radiation or heat
detectors. The confinement of the ferroelectric materials into the
pores (e.g., interconnected pores) of the small porous wires may
enhance their performance or stability, or allow formation of 1D
(wire-shaped) ferroelectric materials or 2D (membrane-shaped)
ferroelectric materials, or may allow attaining multifunctional
properties.
[0119] In some designs, it may be advantageous for the small oxide
wires (including the small wires produced according to the
disclosed methods) to be processed into thermally stable (e.g., to
above 1200.degree. C.) and ultra-strong yards, ropes, sheets, and
fabrics (e.g., based on Al.sub.2O.sub.3, ZrO.sub.2, or MgO small
wires).
[0120] The foregoing description is provided to enable any person
skilled in the art to make or use embodiments of the present
invention. It will be appreciated, however, that the present
invention is not limited to the particular formulations, process
steps, and materials disclosed herein, as various modifications to
these embodiments will be readily apparent to those skilled in the
art. That is, the generic principles defined herein may be applied
to other embodiments without departing from the spirit or scope of
the invention.
* * * * *