Process for Surface Modifications of Tio2 Particles and Other Ceramic Materials

Abstract

A method of preparing a surface modified ceramic material.

1 . A process for making a surface-modified material comprising:
 a. mixing a base material and a phosphate material wherein one of the base material and the phosphate material includes titanium to form a mixture;   b. spray drying the mixture to form a base material with surface having a layer of a titanium phosphate;   c. treating the product of step b with a strong base; and   d. washing the product of step c.   
     
     
         2 . The process of  claim 1  further comprising drying the product after washing. 
     
     
         3 . The process of  claim 2  further comprising calcining the dried product. 
     
     
         4 . The process of  claim 1  further comprising:
 a. contacting the washed product with a strong acid; and   b. subsequently washing the product to form a gelatinous layer of titanium oxide hydrate on the base material.   
     
     
         5 . The process of  claim 4  further comprising drying the product with the gelatinous layer. 
     
     
         6 . The process of  claim 5  further comprising calcining the dried product. 
     
     
         7 . The process of  claim 4  further comprising treating the product with a dopant. 
     
     
         8 . The process of  claim 5  further comprising sequentially treating the dried product with a dopant and then drying. 
     
     
         9 . The process of  claim 8  further comprising calcining the dried product. 
     
     
         10 . The process of  claim 1  where the base material is titanium dioxide. 
     
     
         11 . The process of  claim 1  where the base material is selected from the group consisting of a ceramic metal oxide, a ceramic mixed oxide, a mixed metal oxide, or a mixture thereof. 
     
     
         12 . The process of  claim 11 , where the ceramic metal oxide is selected from the group consisting of TiO 2 , ZrO 2 , Al 2 O 3 , and mixtures thereof. 
     
     
         13 . The process of  claim 8  where the dopant is a noble metal resistant to strong base and strong acid. 
     
     
         14 . The process of  claim 12  where the ceramic metal oxide consists of nano-sized particles with a size between 20 and 100 nm. 
     
     
         15 . The process of  claim 1  where the strong base is KOH. 
     
     
         16 . The process of  claim 4  where the strong acid is HCl. 
     
     
         17 . The process of  claim 7  wherein the dopant is selected from the group consisting of a colloidal metal, a colloidal complex, an organic compound, an inorganic salt, and mixtures thereof. 
     
     
         18 . The process of  claim 4  further comprising:
 a. saturating the surface with a water-soluble organic or inorganic compound;   b. subsequently drying; and   c. calcining.   
     
     
         19 . The process of  claim 4  further comprising:
 a. saturating the surface with a colloid material;   b. subsequently drying; and   c. calcining.   
     
     
         20 . The process of  claim 17  wherein the dopant is a colloidal metal and the final product has a thin metal oxide surface layer.