Method for Manufacturing Silicon Carbide Particles

Shape-Controlled Synthesis of Silicon Carbide Combining Organic Functionalized Silica Templates with Low-Temperature Metallothermic Reduction

This technology uses silica particles modified with organic functional groups, such as alkyl or mercapto groups, as templates. These are mixed with metal and subjected to low-temperature thermal reduction (400–1200°C) followed by acid etching. This allows for precise control over the structure (monolithic or composite) and morphology (spherical, hollow, or rattle-type) of the silicon carbide.

Conventional Acheson processes require ultra-high-temperature equipment exceeding 2000°C, leading to complex processes and high energy consumption. Furthermore, methods for producing hollow or rattle-type particles using external templates involve multiple steps and carry a risk of structural collapse.

This technology involves synthesizing silica particles with attached organic functional groups and independently controlling the type of functional group, thermal reduction time, and heat treatment conditions before and after metallothermic reduction. As a result, monolithic silicon carbide, silicon-carbon composites, and hollow or rattle-type particles can be efficiently obtained without separate templates. Applicable as volume-expansion buffering materials for silicon-based anodes and heat-resistant ceramic fillers, it enables the supply of customized SiC powders with engineered internal voids without the need for high-temperature facility investment.

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Key Features:

• Step 2: Mixing silica particles containing organic functional groups with metal materials and performing thermal reduction to produce silicon carbide particles
• Step 3: Etching the produced silicon carbide particles with an acid solution to reveal their structure and morphology
• Silicon carbide particles controlled to be rattle-type or hollow by adjusting the organic functional group to a mercapto or C1-C4 alkyl group
• Step of mixing water, a basic catalyst, and an alkoxysilane compound containing organic functional groups to generate silica particles through hydrolysis and polycondensation

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