Modified oxygen reduced valve metal oxides
View Patent ↗Pressed material such as anodes are described and formed from oxygen reduced oxide powders using additives, such as binders and/or lubricants. Methods to form the pressed material are also described, such as with the use of atomizing, spray drying, fluid bed processing, microencapsulation, and/or coacervation.
1. Oxygen-reduced valve metal oxide particles having an average primary particle size of from 1 micron to 10.5 microns and a flow of from about 20 mg/s to about 270 mg/s, wherein said oxygen-reduced valve metal oxide particles are oxygen-reduced niobium oxide particles.
2. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles have a specific surface area of from about 0.5 m 2 /g or higher.
3. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles have a specific surface area of from about 1.0 to about 10 m 2 /g.
4. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said specific surface area is from about 2.0 to about 10 m 2 /g.
5. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles have a specific surface area of from about 1.0 to about 2.0 m 2 /g.
6. The oxygen-reduced valve oxide particles of claim 1 , wherein said particles have an apparent density of less than about 2.0 g/cc.
7. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles have an apparent density of less than about 1.5 g/cc.
8. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles have an apparent density of from 0.5 to about 1.5 g/cc.
9. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles, when formed into an anode, have a capacitance capability of from 1,000 to about 62,000 CV/g.
10. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said particles, when formed into an anode, have a capacitance capability of from about 62,000 to about 300,000 CV/g.
11. Agglomerated oxygen-reduced valve metal oxide comprising agglomerate sizes of less than 425 microns, including agglomerate sizes from 150 to 300 microns, wherein said agglomerated oxygen-reduced valve metal oxide is oxygen-reduced niobium oxide.
12. The agglomerated oxygen-reduced valve metal oxide of claim 11 , comprising agglomerate sizes of less than 300 microns, including agglomerate sizes of from 150 to 300 microns.
13. Agglomerated oxygen-reduced valve metal oxide having a flow of from about 20 mg/s to about 270 mg/s.
14. The agglomerated oxygen-reduced valve metal oxides of claim 13 , wherein said oxygen-reduced valve metal oxide is aluminum oxide.
15. The agglomerated oxygen-reduced valve metal oxide of claim 13 , wherein said oxygen-reduced valve metal oxide is tantalum oxide.
16. The agglomerated oxygen-reduced valve metal oxide of claim 13 , wherein said oxygen-reduced valve metal oxide is a titanium oxide.
17. The agglomerated oxygen-reduced valve metal oxide of claim 13 , wherein said oxygen-reduced valve metal oxide is zirconium oxide.
18. The agglomerated oxygen-reduced valve metal oxide of claim 13 , wherein said oxygen-reduced valve metal oxide is vanadium oxide.
19. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
20. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said oxygen-reduced niobium oxide is NbO 0.7 , NbO, NbO 1.1 , or combinations thereof.
21. The oxygen-reduced valve metal oxide particles of claim 3 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
22. The oxygen-reduced valve metal oxide particles of claim 3 , wherein said oxygen-reduced niobium oxide is NbO 0.7 , NbO, NbO 1.1 , or combinations thereof.
23. The oxygen-reduced valve metal oxide particles of claim 6 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
24. The oxygen-reduced valve metal oxide particles of claim 6 , wherein said oxygen-reduced niobium oxide is NbO 0.7 , NbO, NbO 1.1 , or combinations thereof.
25. The oxygen-reduced valve metal oxide particles of claim 4 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
26. The oxygen-reduced valve metal oxide particles of claim 4 , wherein said oxygen-reduced niobium oxide is NbO 0.7 , NbO, NbO 1.1 , or combinations thereof.
27. The oxygen-reduced valve metal oxide particles of claim 5 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
28. The oxygen-reduced valve metal oxide particles of claim 5 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
29. The oxygen-reduced valve metal oxide particles of claim 8 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
30. The oxygen-reduced valve metal oxide particles of claim 8 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
31. The oxygen-reduced valve metal oxide particles of claim 7 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
32. The oxygen-reduced valve metal oxide particles of claim 7 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
33. The oxygen-reduced valve metal oxide particles of claim 10 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
34. The oxygen-reduced valve metal oxide particles of claim 10 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
35. The oxygen-reduced valve metal oxide particles of claim 9 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
36. The oxygen-reduced valve metal oxide particles of claim 9 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
37. The oxygen-reduced valve metal oxide particles of claim 2 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
38. The oxygen-reduced valve metal oxide particles of claim 2 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
39. The agglomerated oxygen-reduced valve metal oxide of claim 11 , wherein said agglomerated oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
40. The agglomerated oxygen-reduced valve metal oxide of claim 11 , wherein said agglomerated oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
41. The agglomerated oxygen-reduced valve metal oxide of claim 12 , wherein said agglomerated oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
42. The agglomerated oxygen-reduced valve metal oxide of claim 12 , wherein said agglomerated oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
43. The agglomerated oxygen-reduced valve metal oxide of claim 13 , wherein said agglomerated oxygen-reduced valve metal oxide is oxygen-reduced niobium oxide.
44. The agglomerated oxygen-reduced valve metal oxide of claim 43 , wherein said agglomerated oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
45. The agglomerated oxygen-reduced valve metal oxide of claim 43 , wherein said agglomerated oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
46. Oxygen-reduced niobium oxide particles having an average particle size of from 1 micron to 10.5 microns, having a flow of from about 20 mg/s to about 270 mg/s, a specific surface area of about 0.5 m 2 /g or higher, an apparent density of less than about 2.0 g/cc, and a capacitance of from 20,000 CV/g to about 300,000 CV/g when formed into an anode with a press density of 3.5 g/cc, a sintering temperature of 1,300° C. for 10 minutes, a formation voltage of 30 volts, and a formation temperature of 60° C.
47. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is less than 2 and y is less than 2.
48. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide is NbO 0.7, NbO, NbO 1.1 , or combinations thereof.
49. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
50. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
51. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide is agglomerated and has agglomerate sizes of less than 425 microns.
52. The oxygen-reduced niobium oxide particles of claim 51 , wherein said agglomerate size is less than 300 microns.
53. The oxygen-reduced niobium oxide particles of claim 51 , wherein said agglomerate size is from 150 to 300 microns.
54. The oxygen-reduced niobium oxide particles of claim 46 , wherein said particles have a specific surface area of from about 1.0 to about 10 m 2 /g.
55. The oxygen-reduced niobium oxide particles of claim 46 , wherein said specific surface area is from about 2.0 to about 10.0 m 2 /g.
56. The oxygen-reduced niobium oxide particles of claim 46 , wherein said particles have a specific surface area of from about 1.0 to about 1.5 m 2 /g.
57. The oxygen-reduced niobium oxide particles of claim 46 , wherein said particles have an apparent density of from 0.5 to about 1.5 g/cc.
58. The oxygen-reduced niobium oxide particles of claim 46 , wherein said particles, when formed into an anode, have a capacitance of from about 62,000 to about 200,000 CV/g.
59. The oxygen-reduced niobium oxide particles of claim 46 , wherein said powder when formed into said anode has a DC leakage of 5.0 nA/CV or less.
60. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
61. The oxygen-reduced valve metal oxide particles of claim 1 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
62. The oxygen-reduced valve metal oxide particles of claim 2 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
63. The oxygen-reduced valve metal oxide particles of claim 2 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
64. The oxygen-reduced valve metal oxide particles of claim 3 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
65. The oxygen-reduced valve metal oxide particles of claim 3 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
66. The oxygen-reduced valve metal oxide particles of claim 4 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
67. The oxygen-reduced valve metal oxide particles of claim 4 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
68. The oxygen-reduced valve metal oxide particles of claim 5 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
69. The oxygen-reduced valve metal oxide particles of claim 5 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
70. The oxygen-reduced valve metal oxide particles of claim 6 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
71. The oxygen-reduced valve metal oxide particles of claim 6 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
72. The oxygen-reduced valve metal oxide particles of claim 8 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
73. The oxygen-reduced valve metal oxide particles of claim 8 , wherein said oxygen-reduced niobium oxide particles have the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
74. The agglomerated oxygen-reduced valve metal oxide of claim 11 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
75. The agglomerated oxygen-reduced valve metal oxide of claim 11 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
76. The agglomerated oxygen-reduced valve metal oxide of claim 12 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
77. The agglomerated oxygen-reduced valve metal oxide of claim 12 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
78. The agglomerated oxygen-reduced valve metal oxide of claim 43 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
79. The agglomerated oxygen-reduced valve metal oxide of claim 43 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
80. The oxygen-reduced niobium oxide particles of claim 51 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
81. The oxygen-reduced niobium oxide particles of claim 51 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
82. The oxygen-reduced niobium oxide particles of claim 54 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
83. The oxygen-reduced niobium oxide particles of claim 54 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
84. The oxygen-reduced niobium oxide particles of claim 65 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
85. The oxygen-reduced niobium oxide particles of claim 65 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to 1.1.
86. The oxygen-reduced niobium oxide particles of claim 57 , wherein said oxygen-reduced niobium oxide has the formula Nb x O y wherein x is 1 and y is 0.7 to less than 2.
87. The agglomerated oxygen-reduced valve metal oxide of claim 45 , wherein said agglomerated particles are formed from oxygen-reduced niobium oxide particles having an average primary particle size of from 1 micron to 10.5 microns.
88. The oxygen-reduced niobium oxide particles of claim 46 , wherein said oxygen-reduced niobium oxide particles have a primary particle size of from 1 micron to 10.5 microns and are agglomerated and have agglomerate sizes of less than 425 microns.