Method and apparatus for forming nano-particles

Abstract

Nano-scale particles of materials can be produced by vaporizing the material and allowing the material to flow in a non-violently turbulent manner into thermal communication with a cooling fluid, thereby forming small particles of the material that can be in the nano-scale size range.

1 . A nano-scale particle generator comprising:
 a first heating device disposed in the chamber and configured to vaporize a raw material; and   a cooling gas source configured to direct a flow of cooling gas into thermal communication with a flow of raw material vapor emanating from the first heating device under substantially free convection.   
     
     
         2 . The generator according to  claim 1  further comprising a chamber, the first heating device being disposed in the chamber. 
     
     
         3 . The generator according to  claim 1 , wherein the cooling gas source is further configured to direct the flow of cooling gas at a speed about the same as a speed of the flow of raw material vapor 
     
     
         4 . The generator according to  claim 1  additionally comprising a vacuum device connected to an upper portion of the chamber and configured to draw cooling gas and nano-scale particles of the raw material from the chamber. 
     
     
         5 . The generator according to  claim 1 , wherein at least one of the first heater device and the cooling gas supply are configured to allow the raw material vapor and cooling gas to rise above the first heater device in a substantially laminar flow. 
     
     
         6 . The generator according to  claim 1  additionally comprising a diffuser disposed at a position below the first heater device. 
     
     
         7 . The generator according to  claim 6 , wherein the diffuser comprises sintered stainless steel. 
     
     
         8 . The generator according to  claim 6 , wherein the diffuser is configured to generate an upward flow of cooling gas being substantially uniform around the first heater device. 
     
     
         9 . The generator according to  claim 1 , wherein the first heater device is configured to allow the raw material to flow, in a liquid state, substantially evenly over a stationary surface of the first heater device. 
     
     
         10 . The generator according to  claim 9 , wherein the first heater device is further configured to transfer sufficient heat through the stationary surface into the liquid raw material to cause the liquid raw material to vaporize. 
     
     
         11 . The generator according to  claim 10 , wherein the stationary surface is configured to transfer heat into the liquid raw material so as to cause vaporization of the liquid raw material at a substantially uniform rate over the stationary surface. 
     
     
         12 . The generator according to  claim 1 , wherein the first heating device is configured to prevent disruption of the flow of raw material vapor emanating therefrom. 
     
     
         13 . The generator according to  claim 1  additionally comprising a second heating device disposed in the chamber and configured to vaporize additional raw material. 
     
     
         14 . The generator according to  claim 13 , wherein the second heating device disposed in the chamber is spaced from and adjacent to the first heating device.