Process for preparing aluminum nitride powder via controlled combustion nitridation

Claim 2

A process for preparing aluminum nitride powder which comprises passing particulate aluminum metal and a nitrogen source through a heated reaction zone, said zone being maintained at a temperature sufficient to individually heat substantially all of the aluminum metal particles at a heating rate of at least about 100 K. per second to a temperature within a temperature range of from about 1873 K. to about 2373 K., at a rate of flow sufficient to maintain substantially all of the aluminum metal particles within said temperature range for a time period of from about 0.2 to about 10 seconds, the time period being sufficient to convert the particulate aluminum metal to a product having an aluminum nitride content of at least about 75 percent by weight, based upon product weight, the aluminum nitride having a surface area within a range of from about 2 to about 8 square meters per gram and an oxygen content within a range of greater than 0 to less than about 1.2 percent by weight, based upon aluminum nitride weight, of monatomic oxygen.

Claim 3

The process of claim 1 wherein the particulate aluminum metal enters the heated reaction zone at a velocity of at least 10 meters per second.

Claim 4

The process of claim 1 further comprising a sequential step wherein the particulate product is passed into a cooling zone after it exits the heated reaction zone and quenched to a temperature below that at which particulate aluminum metal is converted to aluminum nitride.

Claim 5

The process of claim 3 wherein the product is quenched within a time of from about 0.1 second to about 4 minutes after said product exits the heated reaction zone.

Claim 6

The process of claim 3 wherein the time is from about 0.1 second to about 2 minutes.

Claim 7

The process of claim 3 wherein argon gas is fed into the cooling zone to quench the reaction.

Claim 8

The process of claim 3 wherein the cooling rate is at least 100 K. per second.

Claim 9

The process of claim 3 wherein the cooling rate is from about 100 K. to about 10,000,000 K. per second.

Claim 10

The process of claim 3 wherein the cooling rate is from about 1,000 K. to about 10,000,000 K. per second.

Claim 11

The process of claim 3 wherein the cooling rate is from about 10,000 K. to about 1,000,000 K. per second.

Claim 12

The process of claim 1 wherein the aluminum metal particles are maintained within the temperature range for a period of from about 2 to about 8 seconds.

Claim 13

The process of claim 11 wherein the time period is from about 4 to about 6 seconds.

Claim 14

The process of claim 1 wherein the heating rate is from about 100 K. to about 10,000,000 K. per second.

Claim 15

The process of claim 13 wherein the heating rate is from about 1,000 K. to about 10,000,000 K. per second.

Claim 16

The process of claim 13 wherein the heating rate is from about 10,000 K. to about 1,000,000 K. per second.

Claim 17

The process of claim 1 further comprising a sequential step wherein the product is milled to expose unreacted aluminum metal and then heated, in the presence of gaseous nitrogen, to a temperature of from about 1173 K. to about 1873 K. for a period of time sufficient to convert substantially all of the exposed, unreacted aluminum metal surfaces to aluminum nitride.

Claim 18

The process of claim 16 wherein the milling step and secondary heating step are combined and carried out simultaneously.

Claim 19

A process for preparing aluminum nitride powder which comprises passing an admixture of a powdered compatible or removable solid material and particulate aluminum metal and a nitrogen source through a heated reaction zone, the compatible or removable solid material being present in an amount sufficient to reduce deposition of aluminum nitride product upon surfaces which define the reaction zone, said zone being maintained at a temperature sufficient to individually heat substantially all of the aluminum metal particles at a heating rate of at least about 100 K. per second to a temperature within a temperature range of from about 1873 K. to about 2373 K., at a rate of flow sufficient to maintain substantially all of the aluminum metal particles within said temperature range for a time period of from about 0.2 to about 10 seconds, the time period being sufficient to convert the particulate aluminum metal to a product having an aluminum nitride content of at least about 75 percent by weight, based upon product weight, the aluminum nitride having a surface area within a range of from about 0.5 to about 6 square meters per gram and an oxygen content within a range of greater than 0 to less than about 1 percent by weight.

Claim 20

A process for preparing aluminum nitride powder which comprises passing an admixture of a powdered compatible or removable solid material and particulate aluminum metal and a nitrogen source through a heated reaction zone, the compatible or removable solid material being present in an amount sufficient to reduce deposition of aluminum nitride product upon surfaces which define the reaction zone, said zone being maintained at a temperature sufficient to individually heat substantially all of the aluminum metal particles at a heating rate of at least about 100 K. per second to a temperature within a temperature range of from about 1873 K. to about 2373 K., at a rate of flow sufficient to maintain substantially all of the aluminum metal particles within said temperature range for a time period of from about 0.2 to about 10 seconds, the time period being sufficient to convert the particulate aluminum metal to a product having an aluminum nitride content of at least about 75 percent by weight, based upon product weight, the aluminum nitride having a surface area within a range of from about 0.5 to about 6 square meters per gram and an oxygen content within a range of greater than 0 to less than about 1 percent by weight.

Claim 21

The process of claim 18 wherein the compatible material is aluminum nitride.

Claim 22

The process of claim 18 wherein the removable material is carbon.

Claim 23

The process of claim 18 wherein the compatible material is silicon carbide, boron nitride, boron carbide, titanium diboride, silicon nitride, titanium nitride, titanium carbide, or tantalum nitride.

Claim 24

The process of claim 18 further comprising a sequential step wherein the product is milled to expose unreacted aluminum metal and then heated, in the presence of gaseous nitrogen, to a temperature of from about 1173 K. to about 1873 K. for a period of time sufficient to reduce product surface area by at least 10%.

Claim 25

The process of claim 18 further comprising a sequential step wherein its product is simultaneously milled to expose unreacted aluminum metal and heated, in the presence of gaseous nitrogen, to a temperature of from about 1173 K. to about 1873 K. for a period of time sufficient to reduce product surface area by at least 10%.

Claim 26

A multi-step process for preparing aluminum nitride powder which comprises: a) passing an admixture of a previously prepared aluminum nitride power and particulate aluminum metal and a nitrogen source through a heated reaction zone, the previously prepared aluminum nitride powder solid material being present in an amount sufficient to reduce deposition of aluminum nitride product upon surfaces within the reaction zone, said zone being maintained at a temperature sufficient to individually heat substantially all of the aluminum metal particles at a heating rate of at least about 100 K. per second to a temperature within a temperature range of from 1873 K. to about 2373 K., at a rate of flow sufficient to maintain substantially all of the aluminum metal particles within said temperature range for a time period of from about 0.2 to about 10 seconds, the time period being sufficient to convert the particulate aluminum metal to a product having an aluminum nitride content of at least about 75 percent by weight, based upon product weight, the aluminum nitride having a surface area within a range of from about 0.5 to about 6 square meters per gram and an oxygen content within a range of greater than 0 to less than about 1 percent by weight; b) milling the product for a period of time sufficient to expose substantially all unreacted aluminum metal surfaces; c) recycling a portion of the milled product for admixture with powdered aluminum metal; d) heating the milled product, less the recycled portion, in the presence of gaseous nitrogen, to a temperature of from about 1173 K. to about 1873 K. for a period of time sufficient to convert substantially all of the exposed, unreacted aluminum metal surfaces to aluminum nitride.

Claim 27

A multi-step process for preparing aluminum nitride powder which comprises: a) passing an admixture of a previously prepared aluminum nitride power and particulate aluminum metal and a nitrogen source through a heated reaction zone, the previously prepared aluminum nitride powder solid material being present in an amount sufficient to reduce deposition of aluminum nitride product upon surfaces within the reaction zone, said zone being maintained at a temperature sufficient to individually heat substantially all of the aluminum metal particles at a heating rate of at least about 100 K. per second to a temperature within a temperature range of from 1873 K. to about 2373 K., at a rate of flow sufficient to maintain substantially all of the aluminum metal particles within said temperature range for a time period of from about 0.2 to about 10 seconds, the time period being sufficient to convert the particulate aluminum metal to a product having an aluminum nitride content of at least about 75 percent by weight, based upon product weight, the aluminum nitride having a surface area within a range of from about 0.5 to about 6 square meters per gram and an oxygen content within a range of greater than 0 to less than about 1 percent by weight; b) milling the product for a period of time sufficient to expose substantially all unreacted aluminum metal surfaces; c) recycling a portion of the milled product for admixture with powdered aluminum metal; d) heating the milled product, less the recycled portion, in the presence of gaseous nitrogen, to a temperature of from about 1173 K. to about 1873 K. for a period of time sufficient to convert substantially all of the exposed, unreacted aluminum metal surfaces to aluminum nitride.

Claim 28

The process of claim 24 wherein the aluminum nitride-containing product is quenched within a time of from about 0.1 second to about 4 minutes after said product exits the heated reaction zone, but before said product is milled.

Claim 29

The process of claim 25 wherein the time is from about 0.1 second to about 2 minutes.