Gel processing

C. J. Brinker and G. W. Scherer, Sol-Gel-Science The Physics and Chemistry of Sol-Gel Processing Academic Press, San Diego, Calif., 1990. 

Sol—Gel Sintered Aluminum Oxide. A new and much more versatile sintered alumina abrasive is now produced from aluminum monohydrate, with or without small additions of modifiers such as magnesia, by the sol—gel process (see Sol-gel technology). The first modified sol—gel abrasive on the market, Cubitron, was patented (27) and produced by the 3M Corporation for products such as coated belts and disks. The success of this material promoted intensive research into sol—gel abrasives. 

The precursor glass powders may be produced by various methods, the simplest being the milling of quenched glass to an average particle size of 3—15 p.m. Sol gel processes, in which highly uniform, ultrafine amorphous particles are grown in a chemical solution, may be preferable for certain apphcations. 

Sodium Poly(4-styrene sulfonate). The sol—gel processing of TMOS in the presence of sodium poly-4-styrene sulfonate (NaPSS) has been used to synthesize inorganic—organic amorphous complexes (61). These sodium siUcate materials were then isotherm ally crystallized. The processing pH, with respect to the isoelectric point of amorphous siUca, was shown to influence the morphology of the initial gel stmctures. Using x-ray diffraction, the crystallization temperatures were monitored and were found to depend on these initial microstmctures. This was explained in terms of the electrostatic interaction between the evolving siUcate stmctures and the NaPSS prior to heat treatment at elevated temperatures. 

Figure 17 summarizes the avadable sol—gel processes (56). The process on the right of the figure involves the hydrolysis of metal alkoxides in a water—alcohol solution. The hydrolyzed alkoxides are polymerized to form a chemical gel, which is dried and heat treated to form a rigid oxide network held together by chemical bonds. This process is difficult to carry out, because the hydrolysis and polymerization must be carefully controlled. If the hydrolysis reaction proceeds too far, precipitation of hydrous metal oxides from the solution starts to occur, causing agglomerations of particulates in the sol. 

The sol—gel technique has been used mosdy to prepare alumina membranes. Figure 18 shows a cross section of a composite alumina membrane made by sHp coating successive sols with different particle sizes onto a porous ceramic support. SiUca or titanium membranes could also be made by the same principles. Unsupported titanium dioxide membranes with pore sizes of 5 nm or less have been made by the sol—gel process (57). 

Titanium alkoxides are used for the hardening and cross-linking of epoxy, siUcon, urea, melamine, and terephthalate resins in the manufacture of noncorrodable, high temperature lacquers in the sol-gel process as water repellents and adhesive agents (especially with foils) to improve glass surfaces as catalyst in olefin polymeri2ation, and for condensation and esterification. 

W. Lacourse andS. Kim, Use of Mixed Titanium Alkoxides for Sol-Gel Process, Wiiey-ln.tetscien.ee,New York, 1986, pp. 285—303. 

Transparent Vitreous Silica. Clear, transparent, bubble-free vitreous sihca may be obtained by melting natural quart2 minerals, ie, fused quart2, by flame or plasma vapor deposition (synthetic fused siUcas), and by sol—gel processing. 

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