Preparation of intermetallics by metallo-organic decomposition

Patent metadata

Field	Value
Publication number	US-9034431-B2
Application number	US-48816909-A
Country	US
Kind code	B2
Filing date	Jun 19, 2009
Priority date	Jun 13, 2003
Publication date	May 19, 2015
Grant date	May 19, 2015

Abstract

A metallo-organic decomposition process for the preparation of intermetallic powders and films. A liquid mixture containing a first metal precursor and a second metal is heated to a temperature in a first temperature range so as to convert the first metal precursor to a first metal followed by heating to a temperature in a second temperature range so as to form an intermetallic compound by a solid state reaction between the first and second metals. The intermetallic compound can be used as a catalyst in cut filler and/or the filter of a cigarette.

First claim

What is claimed is:

1. A method of making an iron aluminide intermetallic compound comprising:
forming a liquid mixture containing a first metal precursor and a second metal;
applying the liquid mixture to a support;
preparing a powder mixture by heating the liquid mixture to a temperature in a first temperature range of from about 200 to 350° C. so as to dry the liquid mixture and convert the first metal precursor to a first metal; and
heating the powder mixture to a temperature in a second temperature range of from about 400 to 750° C. so as to form an iron aluminide intermetallic compound film on the support by a solid state reaction between the first and second metals,
wherein the first metal precursor comprises a metallo-organic compound.

2. The method according to claim 1 , comprising combining the second metal with the first metal precursor wherein the first metal precursor consists essentially of a metallo-organic compound.

3. The method according to claim 2 , wherein the metallo-organic compound is selected from the group consisting of ethyl hexanoates, acetyl acetonates, oxalates and citrates.

4. The method according to claim 1 , comprising forming a liquid mixture that consists essentially of the first metal precursor, the second metal and a solvent.

5. The method according to claim 1 , wherein the support is selected from the group consisting of a ceramic, metal, plastic or paper.

6. The method according to claim 1 , wherein the support is porous.

7. The method according to claim 1 , wherein the liquid mixture is applied to the support by spraying, dipping or spin coating.

8. The method according to claim 1 , wherein the step of applying the liquid mixture to the support and the step of heating the liquid mixture are performed simultaneously.

9. The method according to claim 1 , wherein the support is selected from the group consisting of silica gel beads, carbon/graphite foam, activated carbon and cut filler.

10. The method according to claim 1 , further comprising forming a liquid mixture that comprises a polymer former.

11. The method according to claim 1 , wherein the steps of heating comprise infrared heating or furnace heating.

12. The method according to claim 1 , wherein the step of heating to a second temperature range comprises heating in a non-oxidizing atmosphere.

13. The method according to claim 1 , wherein the step of applying the liquid mixture to the support and the step of heating the liquid mixture comprise heating in a non-oxidizing atmosphere.

14. The method of claim 1 , wherein the step of applying the liquid mixture to the support and the step of heating the liquid mixture comprise heating in a reducing atmosphere.

15. The method according to claim 1 , wherein the step of applying the liquid mixture to the support and the step of heating the liquid mixture comprise heating at about atmospheric pressure.

16. A method of making an iron aluminide intermetallic compound comprising:
forming a mixture containing a solvent, a first metal precursor and a second metal;
applying the liquid mixture to a support; and
preparing an iron aluminide film on the support by heating the mixture to a decomposition temperature of about 200° C. to about 350° to initiate reduction of metal constituents in the first metal precursor to a first metal and heating the at least partially reduced first metal precursor and the second metal to a reaction temperature from about 450° C. to 750° C. to form an amorphous and/or crystalline iron aluminide intermetallic film on the support by a solid state reaction between the first metal and the second metal; and
wherein the first metal precursor comprises metal alkoxides, β-diketonates, carboxylates, citrates, metal hydrides, thiolates, amides, nitrates, carbonates, oxalates and/or hydrates thereof.

17. The method according to claim 16 , wherein the first metal precursor is selected from the group consisting of ethyl hexanoates, acetyl acetonate, and citrates.

Assignees

• Deevi Sarojini
• Pithawalla Yezdi B
• Philip Morris Usa Inc

Inventors

• Deevi Sarojini
• Pithawalla Yezdi B

Classifications

• C22C1/047

  comprising intermetallic compounds {(C22C1/0441 takes precedence)} · CPC title

• A24B15/287

  by inorganic substances only · CPC title

• B01J23/80

  with zinc, cadmium or mercury · CPC title

• B22F9/24

  starting from liquid metal compounds, e.g. solutions · CPC title

• B22F1/0018

  Operations & Transport · mapped topic