Ultrapure, Spherical, Monodisperse, Unagglomerated Nanopowders for Infrared Window Materials

Physical Sciences Inc. (PSI) proposes to fabricate high quality ceramic nanoparticles using an electrostatically controlled spray process. Although the commercial production of nanoparticles has steadily increased over the last several years, the use ofnanoparticles for optical ceramic fabrication has been limited. Theoretical expectations have not been met with existing methods due to particle impurities, broad size distributions, and shape anomalies. In the proposed process, cost-effective ultra-highpurity reagents and streamlined handling methods will be used to synthesize the materials. The integration of electrostatic control during the formation, transportation, and collection of the particles will be used to assure high quality and efficiency ismaintained. At the point of particle formation the development of a multi-element array will increase product throughput to reach suggested manufacturing levels. Successful completion of the Phase 1 program will demonstrate the production ofmonodisperse, sub-25 nm, high-purity ceramic nanoparticles meeting the need for improved ceramic materials. The total world market for nanoparticulate materials reached $492.5 million in 2000 and is expected to grow at an average annual rate of 12.8% overthe next 5 years. Consumers include both commercial and military companies. A partial list of applications for ceramic nanomaterials currently includes uses as abrasives, phosphors, fuel cells, cosmetics, and hard coatings. Success of the proposedtechnology will allow the nanopowders produced to gain immediate acceptance into existing markets. Additionally, new markets within the areas of structural ceramics and optics will be formed.