Ultra-low expansion glass from gels

Pyrolysis of mixed titanium and silicon metal halides produces a commercial glass (7.4% TiO₂) with ultra-low thermal expansion that is essentially zero over the temperature range of 0 to 300°C. A colloidal particulate gel process involving potassium silicate, titania sol and formamide gel reagent was found to produce glass compositions with similar low expansion behavior. Due to the strongly basic nature of the precursor solutions, special titania sols had to be prepared that were stable in these alkali silicate solutions. The preferred TiO₂ sols were those containing quaternary ammonium stabilizing counter-ions. These sols served not only as the source of homogeneously distributed titania, but they may also serve as nucleating species that contribute to particle growth and pore size control of the gel network. The large pore (0.3 µm) TiO₂/SiO₂ gel structures were easily dealkalized, dried and sintered to uncracked glass shapes. Plates up to 9.5 cm×6.6 cm× 0.5 cm thick and some intricate cast shapes were produced and their glass properties evaluated.     

Densification and crystallisation of celsian glass derived from alkoxide gel

High density (98% of theoretical) was achieved at 900°C for an all-alkoxide derived bulk celsian gel prior to crystallisation. TEM indicated that crystallisation was dominated by volume nucleation and growth of hexagonal disc shaped hexacelsian. Kinetic studies using SEM indicate a maximum nucleation rate at 980°C and an activation energy for crystal growth of 566 KJ/mol. The high rates of densification and of nucleation are attributed to the high OH content in the gel-derived glass.     

Microstructural and Dielectric Characterization of Sol-Gel Derived Silicon Oxycarbide Glass Sheets

Thin (50—1000 m) silicon oxycarbide glass sheets were synthesized by the pyrolysis of gel sheets obtained from a methyl-modified silica sol containing colloidal silica under inert atmosphere between 900 and 1450°C. The microstructure of these glass sheets was investigated with the help of high resolution scanning and transmission electron microscopy (HR-SEM and HR-TEM), X-ray diffraction and Raman spectroscopy and their dielectric properties were determined. The surface morphology as observed with HR-SEM did not exhibit a notable temperature dependence. HR-TEM studies showed that the glass sheets sintered up to 1200°C are amorphous, whereas those sintered at 1450°C contain uniformly dispersed crystallites of SiC and graphite. X-ray diffraction studies were found in agreement with the HR-TEM results. Raman spectroscopy showed that free carbon is present as an amorphous phase till a temperature of 1000°C, whereas at temperatures 1200°C, the presence of graphitic carbon was observed. Silicon oxycarbide glass sheets heat treated at temperatures up to 1200°C, showed a dielectric constant between 4.1 ± 0.11 and 4.6 ± 0.15 in the frequency range from 75 kHz to 5 MHz, with corresponding losses between 0.0008 and 0.1100. Such silicon oxycarbide glass sheets sintered at 1200°C could find an application as substrates for electronic packaging.     

Production of anomalously shaped carboxylated polymer particles by seeded emulsion polymerization

Anomalous polymer particles with a partial protuberance like octopus ocellatus were produced under alkaline conditions by seeded emulsion copolymerization for styrene and butyl acrylate, with styrene-butyl acrylate-methacrylic acid terpolymer emulsion as seed. The mechanism of production of the polymer particles was studied. By transmission electron microscopic observation of the particles at each conversion, it was observed that the anomalous polymer particles were produced by partial growth of each of the individual seed particles throughout polymerization. Ionization of the carboxyl groups and low viscosity in the growing particles during the process of polymerization were important factors for partial growth.Part CIII of the series Studies on Suspension and Emulsion.     

Sol-Gel Synthesis and Microstructural Characterization of Silicon Oxycarbide Glass Sheets with High Fracture Strength and High Modulus

A synthesis route to silicon oxycarbide glass sheets (thickness 40 to 1000 m and area up to 20 × 35 cm2) has been developed for the first time starting from a methyl modified sol containing nano-particulate SiO2 and having a solid content of 70 wt%. The gel sheets obtained by casting and drying of this sol were sintered in N2 atmosphere at temperatures between 900–1650°C. Only by the incorporation of colloidal silica (0.10–0.35 mole per mole alkoxide) to the sol could crack-free, large area glass sheets be obtained. Fracture strength (three point bending) was found to attain a maximum (200–300 MPa) for the sheets sintered at 1000°C. Young's modulus attained a peak value between 120 and 130 GPa for the sheets sintered at 1200°C. HR-TEM studies showed an amorphous and homogeneous matrix up to a sintering temperature of 1200°C, whereas at 1450°C and 1650°C, crystallites of SiC and lamellar graphite were formed. It is concluded that addition of colloidal silica to the sol does not lead to inhomogeneities after sintering and therefore does not decrease the strength and elastic modulus.     

Formation of multihollow structures in crosslinked composite polymer particles

Micron-size monodisperse polymer particles having multihollow structures were prepared as follows. First, micron-size monodisperse polystyrene/poly(styrene-divinylbenzene) (PS/P(S-DVB)) composite particles were produced by seeded copolymerization of S and DVB with 2,2-azobisisobutyronitrile as an initiator in the ethanol/water (76/24, weight ratio) medium in the presence of 2.37 m-size monodisperse PS seed particles produced by dispersion polymerization. The molar ratio of S/DVB was changed in the range of 1/110/1. The uncrosslinked polymer within the composite particles was extracted with toluene under reflux. For the highest DVB content (S/DVB=1/1, molar ratio), one large hollow was observed in a part of the composite particles after the extraction. For the middle DVB content (S/DVB=4/1, molar ratio), multihollow structure was observed in all the particles. For the lowest DVB content (S/DVB=10/1, molar ratio), fine multihollow structure was observed in all the particles.Part CXLIII of the series Studies on Suspension and Emulsion     

Processing and properties of sintered submicron IR transparent alumina derived through sol–gel method

For the first time, sintered alumina with high transparency in mid infrared region, composed of submicron grains, has been fabricated using sol–gel processing. Commercially available boehmite powder was used to prepare the stable sol. The sol was mixed with appropriate amount of sintering aids and alumina seeds. The sol was further gelled, dried, and heat treated at 1000?°C for producing alumina powder. The powder was further shaped into pellets by compaction and sintered at temperatures between 1200 and 1400?°C in air. Sintered samples were further pressed hot isostatically to produce sintered submicron transparent alumina. The synthesized powder was characterized for its morphology and phase. The sintered and hot isostatically pressed samples were characterized for their physical, mechanical, and optical properties. The present method produced transparent alumina with transparency upto 87% in mid-wave infrared region. These transparency values were at par with the transparency of single crystal sapphire in the mid-wave infrared region and the hardness values were even superior than sapphire.

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Influences of the locations of monomer and initiator in the seeded polymerization systems on the morphologies of micron-sized monodispersed composite polymer particles

Three kinds of micron-sized monodispersed polystyrene (PS)/poly(n-butyl methacrylate) (PBMA) composite particles (PS/BMA=2/1, wt. ratio) were produced by two kinds of seeded polymerizations ofn-butyl methacrylate (BMA) in the presence of about 2 m-sized monodispersed PS particles, and their morphologies were examined. One was produced by a seeded dispersion polymerization where almost monomers and initiators exist in an ethanol/water (1/1, w/w) medium. The others two were produced by seeded polymerizations utilizing the dynamic swelling method, where almost monomers exist in the PS seed particles, with 2,2-azobisisobutyronitrile initiator in the monomer-swollen particles and with 2,2-azobis [2-(2-imidazolin-2-yl)propane] initiator in an ethanol/water (1/5, w/w) medium. In the former polymerization, the produced composite particles had a core-shell structure consisting of a PS-core and a PBMA-shell, whereas in the latter two polymerizations, they had a POO (Polymeric Oil-in-Oil) structure consisting of a PS-matrix and many PBMA-domains, regardless of the location of initiator in the systems. From these results, it is concluded that the location of BMA monomer in the seeded polymerization systems with micron-sized monodispersed PS seed particles greatly affects the morphologies of produced PS/PBMA composite particles.Part CLI of the series Studies on Suspension and Emulsion     

Application of self seeding technique in regulating polymorphic transformations during non-isothermal bulk crystallization of polymers

Non-isothermal melt crystallization of trans-1,4-polyisoprene (TPIP) has been studied with the help of differential scanning calorimetry (DSC) and wide-angle x-ray diffraction. Self-seeding has been used for the controlled growth of polymorphs. Thus, self-seeding below 55° and below 71°C has led to the exclusive crystallization of and polymorphs, respectively, upon non-isothermal cooling of the polymer melt. These temperatures may vary slightly with the previous thermal history and molecular characteristics of the original sample. It has been interpreted that during cooling the rate of growth (by secondary nucleation) of seeds of either polymorph remains much faster than the rate of primary nucleation of the other polymorph whose seeds are not present in the melt. As a result, the crystallizing melt becomes occupied by the spherulites of the seeded polymorph well before the other polymorph can nucleate.     

Preparation of micron-size monodisperse polymer microspheres having crosslinked structures and vinyl groups

Micron-size monodisperse polymer microspheres having crosslinked structures therein and vinyl groups thereon were prepared by seeded copolymerization of styrene and divinylbenzene with 2,2-azobisisobutyronitrile as initiator in ethanolwater medium in the presence of 2.1-m monodisperse polystyrene seed particles produced by dispersion polymerization. The optimum conditions of the seeded copolymerization for producing the microspheres with good monodispersity and colloidal stability were determined.Part CXXI of the series Studies on Suspension and Emulsion.     

Synthesis and Characterization of PZT Fibers via Sol-Gel

A fiber forming PZT gel containing 58.5 wt% PZT was synthesized by using zirconium-n-propylate, titanium-iso-propylate, lead acetate and butoxyethanol. Unseeded PZT gels and gels containing 0.5 wt% PZT perovskite seeds (Ø = 200–300 nm) could be extruded through a monofilament nozzle (Ø = 100 m) at pressures between 50 and 150 bar, whereas PZT gels, containing 1 and 2 wt% PZT particles, were pressed through the nozzle at higher pressures (200–300 bar). The microstructure of unseeded and seeded (0.5, 1, 2 wt% PZT) PZT fibers was characterized by SEM. Unseeded fibers had three different shells at 450°C: an external dense shell (approx. 200 nm thick), a middle shell consisting of a porous structure (1.5m thick) and the center of the fiber, characterized by a matrix containing globular particles. At 700°C, a 200–250 nm thick and dense external shell and a porous fiber interior were be observed. 2 wt% of PZT seeds was necessary to densify the fiber completely. The seeds were located in the center of each PZT perovskite rosette.     

Facile fabrication of snowman-like Janus particles with asymmetric fluorescent properties via seeded emulsion polymerization

This paper presents a facile method for the preparation of snowman-like Janus particles (SJP) with asymmetric fluorescent property via seeded emulsion polymerization, in which in situ formed raspberry-like cadmium sulfide/poly(styrene–divinylbenzene–acrylic acid) nanocomposite particles (RNP) were used as the seeds. The as-prepared RNP and SJP have been thoroughly characterized by transmission electron microscopy, field-emission scanning electron microscopy, thermogravimetric analysis, X-ray powder diffraction, Fourier transform infrared, ultraviolet visible, and photoluminescent spectrometry. It is found that the size ratio of the polymer bulge/inorganic seed part could be continuously tuned as well as the composition of polymer bulges by changing the composition of monomer mixtures and monomer/seed weight ratio. The obtained Janus particles possess amphiphilic properties which can be further used as solid surfactants to stabilize W/O emulsions and successively to construct hierarchical structured materials. Meanwhile, their asymmetric fluorescent properties may be exploited to detect their assembled situation and orientation at the oil–water interface of emulsions as well as at the surface of hierarchical structured materials.

Diol—Based Sol–Gel as a Novel Binder for Barium Titanate Ceramics

The relative merits of using a diol-based sol–gel precursor as a binder in the fabrication of barium titanate ceramics made by die-pressing a mixed oxide starting powder have been investigated. The characteristics of powder compacts were compared to samples prepared using a conventional PVB organic binder. The green strength of pellets with the PVB binder was higher than for samples containing the gel, but strength after binder burnout from gel samples was double that of pellets made with PVB. The gel led to improvements in densification during sintering, but these were most noticeable at low sintering temperatures and at intermediate stages of densification. After sintering for 2 h at 1150C, the gel-containing samples reached 75% of theoretical density, some 5% more than for the organic polymer binder. Sintering at 1300C for 2 h, gave a sintered density of ~96% of theoretical density using the gel additive, which was only 2% higher than for the conventional PVB binder system. The decomposition characteristics of the gel were investigated by TGA, FTIR and GC-MS techniques.     

Sol-Gel Fabrication and Properties of Silica Cores of Optical Fibers Doped with Yb3+, Er3+, Al2 O3 or TiO2

Optical cores of preforms for drawing optical fibers doped with Er3+ and Yb3+ were fabricated by the sol-gel method with the aim of increasing the thickness of glass layers coated in a single coating cycle and to determine the relation between the preparation conditions and optical properties of the fibers. Al2O3-P2O5-SiO2 and TiO2-P2O5-SiO2 glasses have been studied as matrices for entrapping the rare-earth elements. Input sols have been prepared from silicon and titanium alkoxides, AlCl3, ErCl3, YbCl3, POCl3, water and a modifier under acidic catalysis of HCl. The sols were coated on the inner wall of a silica substrate tube and the gel layers were sintered at high temperatures up to 2000°C after which the tube was collapsed into the preform. Continuous and homogenous glass films with the maximum thickness of about 8 m were fabricated. The influence of high-temperature heat treatment of the layers on their composition and optical attenuation was observed. The amplified stimulated emission of Er3+ around 1.55 m was measured under the excitation of the fibers by an Nd : YAG laser at 1.064 m.     

Synthesis of temperature-sensitive submicron-size composite polymer particles

Temperature-sensitive composite polymer particles were prepared by seeded emulsion copolymerization of dimethylaminoethyl methacrylate and ethylene glycol dimethacrylate with 0.17 m-sized monodispersed polystyrene seed particles. The adsorption and desorption behaviors of low molecular weight cationic emulsifier as well as albumin were examined to determine the variation of surface properties as a function of temperature below and above 35°C.     

Preparation of micron-size monodisperse polymer particles having highly crosslinked structures and vinyl groups by seeded polymerization of divinylbenzene using the dynamic swelling method

Micron-size monodisperse polystyrene/polydivinylbenzene (PS/PDVB) composite particles having highly crosslinked structures and vinyl groups were prepared as follows. First, 1.9 m-size monodisperse PS seed particles produced by dispersion polymerization were dispersed in ethanol/water (70/30, w/w) solution which dissolved divinylbenzene (DVB) monomer, benzoyl peroxide as an initiator and poly(vinyl alcohol) as a stabilizer. The PS seed particles were swollen with a large amount of DVB monomers to 4.3 m in diameter while keeping good monodispersity by the dynamic swelling method, where water was slowly added, continuously, with a micro feeder into the dispersion. And then, the seeded polymerization of the absorbed DVB was carried out.Part CXXXV of the series Studies on Suspension and Emulsion     

Preparation of micron-size monodisperse polymer particles by seeded polymerization utilizing the dynamic monomer swelling method

Utilizing a new type of monomer swelling method, 6.1 m-size monodisperse polymer particles were prepared by seeded polymerization. 1.8 m-size monodisperse polystyrene (PS) seed particles (1.8 m in size) were prepared by dispersion polymerization in ethanol-water (80/20, v/v) medium in the presence of poly(acrylic acid) as stabilizer with 2,2-azobisisobutyronitrile as initiator. The PS seed dispersion was mixed with ethanol-water (60/40, v/v) solution dissolving styrene (S) monomer, benzoyl peroxide as initiator, and poly(vinyl alcohol) as stabilizer. By slow, continuous, dropwise addition of water with a micro feeder into the mixture, the PS particles absorbed the many S monomers, which were separated from the medium and swelled from 1.8 m to 8.4 m while keeping the monodispersity high. We named this procedure the dynamic swelling method. Then, the seeded polymerization of the absorbed S monomer was carried out in the presence of NaNO₂ as water-solube inhibitor.Part CXXII of the series Studies on Suspension and Emulsion.     

Formation mechanism of anomalous “golf ball-like” composite polymer particles by seeded emulsion polymerization

Recently, the authors found that anomalous polystyrene/polybutyl acrylate composite particles, whose surfaces had many dents, were produced by emulsifier-free seeded emulsion polymerization of butyl acrylate with polystyrene seed particles. Such a particle was named a golf ball-like particle. In this article, the morphology and the formation mechanism of the golf ball-like composite polymer particles were studied.Part CLV of the series Studies on Suspension and Emulsion     

Production of monodisperse cerium oxide microspheres with diameters near 100 µm by internal-gelation sol–gel methods

Internal-gelation sol–gel methods have used a variety of sphere-forming methods in the past to produce metal oxide microspheres, but typically with poor control over the size uniformity at diameters near 100?µm. This work describes efforts to make and measure internal-gelation, sol–gel microspheres with very uniform diameters in the 100–200-µm size range using a two-fluid nozzle. A custom apparatus was used to form aqueous droplets of sol–gel feed solutions in silicone oil and heat them to cause gelation of the spheres. Gelled spheres were washed, dried, and sintered prior to mounting them on glass slides for optical imaging and analysis. Microsphere diameters and shape factors were determined as a function of silicone oil flow rate in a two-fluid nozzle and the size of a needle dispensing the aqueous sol–gel solution. Nine batches of microspheres were analyzed and had diameters ranging from 65.5?±?2.4?µm for the smallest needle and the fastest silicone oil flow rate to 211?±?4.7?µm for the largest needle and the slowest silicone oil flow rate. Standard deviations for measured diameters were less than 8% for all samples and most of them were less than 4%. Microspheres had excellent circularity with measured shape factors of 0.9–1. However, processing of optical images was complicated by shadow effects in the photoresist layer on glass slides and by overlapping microspheres. Based on the calculated flow parameters, microspheres were produced in a simple dripping mode in the two-fluid nozzle. Using flow rates consistent with a simple dripping mode in a two-fluid nozzle configuration allows for very uniform oxide microspheres to be produced using the internal-gelation sol–gel method.

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Characteristics of Diffraction Gratings Fabricated by the Two-Beam Interference Method Using Photosensitive Hybrid Gel Films

Diffraction gratings of arbitrary periods have been fabricated by the two-beam interference method using photosensitive ZrO₂ gel films and characterized. The ZrO₂ gel films were formed on Si or silica glass substrates from sols that were derived from Zr-butoxide modified chemically with benzoylacetone. The gel films were irradiated with two interference beams from a He-Cd laser (325 nm) and then leached in ethyl alcohol. The above process gave uniform surface-relief gratings of periods ranging from 1.0 to 0.5 m, depending on the incidence angle of the interference beams. The diffraction efficiency, measured in the Littrow configuration using a He-Ne laser (633 nm), showed polarization dependence for the grating of 0.5 m period but not for the gratings of 1.0 m period. The maximum diffraction efficiency was 18% for the grating of 1.0 m period and 28% for that of 0.5 m period in the reflection mode. The present study has proved that the photosensitive gel films are versatile in fabrication of optical devices.