A continuous flow reactor for the efficient synthesis of nanoparticles with a high degree of crystallinity, uniform particle size, and homogenous stoichiometry throughout the crystal is described. Disclosed embodiments include a flow reactor with an energy source for rapid nucleation of the procurors following precursors to form nucleates followed by a separate heating source for growing the nucleates. Segmented flow may be provided to facilitate mixing and uniform energy absorption of the precursors, and post production quality testing in communication with a control system allow automatic real-time adjustment of the production parameters. The nucleation energy source can be monomodal, multimodal, or multivariable frequency microwave energy and tuned to allow different precursors to nucleate at substantially the same time thereby resulting in a substantially homogenous nanoparticle. A shell application system may also be provided to allow one or more shell layers to be formed onto each nanoparticle.
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1. A method for producing uniformly sized quantum dot nanoparticles comprising:
blending at least a first precursor and at least a second precursor together to form a liquid precursor mixture;
conducting the liquid precursor mixture along a continuous flow path comprising one or more tubes through which the liquid precursor mixture flows, wherein at least one of the one or more tubes comprises an inner diameter of ¼ inch to ½ inch;
introducing gas into the continuous flow path fluidically so as to form partitions of the gas in the continuous flow path;
after introducing the gas into the continuous flow path, activating the liquid precursor mixture with one or more of multimodal and multivariable frequency microwave energy from a microwave energy source along the continuous flow path for a first duration at a first energy level thereby allowing uniform nucleation of quantum dot nucleates in the mixture of precursors;
heating the liquid precursor mixture with a heating source along the continuous flow path for a second duration at a controlled temperature, thereby promoting uniform thermodynamic growth around previously formed the quantum dot nucleates previously formed to form desired core sized nanoparticles core quantum dot nanoparticles, wherein the core quantum dot nanoparticles fluoresce with a full width half max (FWHM) of less than 50 nm at wavelengths from 400 nm-700 nm; and
quenching the growth of the quantum dot nanoparticles after heating.
21. A method for producing uniformly sized quantum dot nanoparticles comprising:
blending together a first and second precursor to form a liquid precursor mixture;
conducting the liquid precursor mixture along multiple lines of a continuous flow path comprising one or more tubes through which the liquid precursor mixture flows, wherein at least one tube of the one or more tubes comprises an inner diameter of ¼ inch to ½ inch;
introducing gas into the continuous flow path fluidically upstream of the microwave energy source, so as to form partitions of the gas in the multiple lines, which separate adjacent segments of the liquid precursor mixture;
activating the liquid precursor mixture with multimodal and/or multivariable frequency microwave energy from a microwave energy source in the continuous flow path, the microwave energy source configured to uniformly irradiate the multiple lines and thereby uniformly nucleate the liquid precursor mixture, for a first duration at a first energy level, to form quantum dot nucleates;
heating the activated liquid precursor mixture with a heating source in the continuous flow path for a second duration at a controlled temperature, thereby promoting uniform thermodynamic growth around previously formed the quantum dot nucleates previously formed to form desired core sized nanoparticles core quantum dot nanoparticles, wherein the core quantum dot nanoparticles fluoresce with a full width half max (FWHM) of less than 50 nm at wavelengths from 400 nm-700 nm; and
quenching the growth of the quantum dot nanoparticles after heating.
4. The method of
5. The method of
10. The method of
11. The method of
wherein Group A includes H2X where X=O, S, Se, Te; R3PX where R=H, (CH2)nCH3, C6H5, C6H4R′, n=3-18, R′=(CH2)mCH3, CH(CH3)2, C(CH3)3, m=0-17, X=Se, Te; R3NX where R=H, (CH2)nCH3, Si(CH3)3, n=0-4, X=S, Se, Te; ((CH3)3Si)2X where X=S, Se, Te; HX(CH2)nCH3 where X=O, S, Se, Te, n=1-18; HO(CH2)(CH(OH))n(CH3) where n=1-50; HO(CH2)(CH(OH))n(CH2OH) where n=1-50; H2NNH2; NaBH4, NaCNBH3; and mixtures thereof including anionic precursors and/or reducing agents,
wherein Group B includes MLy where M=Tl, Ag, Cu when y=1, M=Zn, Cd, Hg, Cu, Pb, Ni when y=2, M=Al, Ga, B, In, Bi, Fe when y=3, L=O2 C(CH2)nCH3, O2C(CH2)mCHCH(CH2)OCH3) O2C(CH2)mCH═CH(CH2)oCH3, S(CH2)nCH3, PR3, OPR3, n=2-24, m and o=1-15, R=(CH2)pCH3, C6H5, C6H4R′, p=0-18, R′=(CH2)pCH3, CH(CH3)2, C(CH3)3; and mixtures thereof, and
wherein Group C includes: MLy where M=Na, K, Rb, Cs, Ag, Cu when y=1, M=Mg, Ca, Sr, Ba, Pd, Pt, Cu, Ni when y=2, M=La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Au when y=3, M=Ti, Zr, Hf, Pt, Pd when y=4, L=O2CCH3, Cl, F, NO3; and mixtures thereof.
12. The method of
13. The method of
using a continuous-flow process to expose the quantum dot nanoparticles to a mixture of at least a third precursor from Group A herein and a fourth precursor from Group B or Group C herein; and
heating the exposed quantum dot nanoparticles in a heat source to form a first shell around the quantum dot nanoparticle,
wherein Group A includes: H2X where X=O, S, Se, Te; R3PX where R=H, (CH2)nCH3, C6H5, C6H4R′, n=3-18, R′=(CH2)mCH3, CH(CH3)2, C(CH3)3, m=0-17, X=Se, Te; R3NX where R=H, (CH2)nCH3, Si(CH3)3, n=0-4, X=S, Se, Te; ((CH3)3Si)2X where X=S, Se, Te; HX(CH2)nCH3 where X=O, S, Se, Te, n=1-18; HO(CH2)(CH(OH))n(CH3) where n=1-50; HO(CH2)(CH(OH))n(CH2OH) where n=1-50; H2NNH2; NaBH4, NaCNBH3; and mixtures thereof including anionic precursors and/or reducing agents,
wherein Group B includes: MLy where M=Tl, Ag, Cu when y=1, M=Zn, Cd, Hg, Cu, Pb, Ni when y=2, M=Al, Ga, B, In, Bi, Fe when y=3, L=O2C(CH)nCH3, O2C(CH2)mCHCH(CH2)OCH3) O2C(CH2)mCH═CH(CH2)oCH3, S(CH2)nCH3, PR3, OPR3, n=2-24, m and o=1-15, R=(CH2)nCH3, C6H5, C6H4R′, p=0-18, R′=(CH2)pCH3, CH(CH3)2, C(CH3)3; and mixtures thereof, and
wherein Group C includes: MLy where M=Na, K, Rb, Cs, Ag, Cu when y=1, M=Mg, Ca, Sr, Ba, Pd, Pt, Cu, Ni when y=2, M=La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Au when y=3, M=Ti, Zr, Hf, Pt, Pd when y=4, L=O2CCH3, Cl, F, NO3; and mixtures thereof.
14. The method of
using a continuous-flow process to expose the quantum dot nanoparticles to a mixture of a fifth precursor and a sixth precursor; and
heating the exposed quantum dot nanoparticle to form a second shell around the first shell.
15. The method of
heating the exposed quantum dot nanoparticle to form a second shell around the first shell,
wherein Group A includes: H2X where X=O, S, Se, Te; R3PX where R=H, (CH2)nCH3, C6H5, C6H4R′, n=3-18, R′=(CH2)mCH3, CH(CH3)2, C(CH3)3, m=0-17, X=Se, Te; R3NX where R=H, (CH2)nCH3, Si(CH3)3, n=0-4, X=S, Se, Te; ((CH3)3Si)2X where X=S, Se, Te; HX(CH2)nCH3 where X=O, S, Se, Te, n=1-18; HO(CH2)(CH(OH))n(CH3) where n=1-50; HO(CH2)(CH(OH))n(CH2OH) where n=1-50; H2NNH2; NaBH4, NaCNBH3; and mixtures thereof including anionic precursors and/or reducing agents,
wherein Group B includes: MLy where M=Tl, Ag, Cu when y=1, M=Zn, Cd, Hg, Cu, Pb, Ni when y=2, M=Al, Ga, B, In, Bi, Fe when y=3, L=O2C(CH2)nCH3, O2C(CH2)mCHCH(CH2)OCH3) O2C(CH2)mCH═CH(CH2)oCH3, S(CH2)CH3, PR3, OPR3, n=2-24, m and o=1-15, R=(CH2)pCH3, C6H5, C6H4R′, p=0-18, R′=(CH2)pCH3, CH(CH3)2, C(CH3)3; and mixtures thereof, and
wherein Group C includes: MLy where M=Na, K, Rb, Cs, Ag, Cu when y=1, M=Mg, Ca, Sr, Ba, Pd, Pt, Cu, Ni when y=2, M=La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Au when y=3, M=Ti, Zr, Hf, Pt, Pd when y=4, L=O2CCH3, Cl, F, NO3; and mixtures thereof.
16. The method of
using a continuous-flow process to expose the quantum dot nanoparticles to a mixture of a seventh precursor from Group A herein and a an eighth precursor from Group B or Group C herein; and
heating the exposed quantum dot nanoparticle to form a third shell around the second shell.
17. The method of
18. The method of
19. The method of
20. The nanoparticle method of
27. The method of
28. The method of
29. The method of
wherein Group A includes: H2X where X=O, S, Se, Te; R3PX where R=H, (CH2)nCH3, C6H5, C6H4R′, n=3-18, R′=(CH2)mCH3, CH(CH3)2, C(CH3)3, m=0-17, X=Se, Te; R3NX where R=H, (CH2)nCH3, Si(CH3)3, n=0-4, X=S, Se, Te; ((CH3)3Si)2X where X=S, Se, Te; HX(CH2)nCH3 where X=O, S, Se, Te, n=1-18; HO(CH2)(CH(OH))n(CH3) where n=1-50; HO(CH2)(CH(OH))n(CH2OH) where n=1-50; H2NNH2; NaBH4, NaCNBH3; and mixtures thereof including anionic precursors and/or reducing agents,
wherein Group B includes: MLy where M=Tl, Ag, Cu when y=1, M=Zn, Cd, Hg, Cu, Pb, Ni when y=2, M=Al, Ga, B, In, Bi, Fe when y=3, L=O2C(CH2)nCH3, O2C(CH2)mCHCH(CH2)OCH3)OCH3) O2C(CH2)mCH═CH(CH2)oCH3, S(CH2)nCH3, PR3, OPR3, n=2-24, m and o=1-15, R=(CH2)pCH3, C6H5, C6H4R′, p=0-18, R′=(CH2)pCH3, CH(CH3)2, C(CH3)3; and mixtures thereof, and
wherein Group C includes: MLy where M=Na, K, Rb, Cs, Ag, Cu when y=1, M=Mg, Ca, Sr, Ba, Pd, Pt, Cu, Ni when y=2, M=La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Au when y=3, M=Ti, Zr, Hf, Pt, Pd when y=4, L=O2CCH3, Cl, F, NO3; and mixtures thereof.
30. The method of
0. 31. The method of
0. 32. The method of
33. The method of
0. 34. The method of
0. 35. The method of claim 1, wherein the continuous flow path comprises multiple flow cell tubes that pass through a same microwave reactor cavity.
0. 36. The method of claim 1, wherein the multivariable frequency microwave energy is tuned to a first frequency for the first precursor and is tuned to a second frequency for the second precursor.
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Where a COV <15% within a single run demonstrates uniform particle size, and a COV <15% from batch-to-batch demonstrates reproducibility.
Degree of Crystallinity and Homogeneous Stoichiometry: The degree of crystallinity or the purity of the crystalline phase (as shown in
Homogeneous Stoichiometry and Uniform Particle Size: This information is obtained using either absorbance spectrophotometry or photoluminescent emission. The absorption and photoluminescence characteristics of a nanoparticle are determined by the FWHM (full width half max, where the width of the absorbance or photoluminescence peak is determined at half the height of the peak of interest) obtained through the spectrum. An increase in the FWHM means that one of multiple effects could be taking place, such as: large particle size distribution (COV >15%), insufficient degree of crystallinity resulting in trap states that have different energies than a highly crystalline nanoparticle, and inhomogeneity of the material—giving rise to multiple excitations or emissions from the various regions within the nanoparticle or batch of nanoparticles. A nanoparticle having a high degree of crystallinity, a homogeneous stoichiometry, and being monodisperse will give rise to absorption and/or photoluminescence peaks of: <50 nm FWHM from 400 nm-700 nm, <150 nm FWHM from 700 nm-2000 nm, <300 nm FWHM from 2000 nm-10000 nm.
In the case of metallic nanoparticles, instead of a first exciton excitation and emission, a surface resonance plasmon can be observed. Using the same arguments presented above, a metallic nanoparticle having a high degree of crystallinity will have <50 nm FWHM when excited at the surface plasmon resonance frequency when excited between 400 nm and 700, and <150 nm FWHM when excited in the near-infrared range (700 nm-2000 nm) when exciting at the surface plasmon resonance frequency.
The frequency or frequencies which the microwave operates can also be selected to excite a particular material in the process without exciting other materials such as binders or the like. Microwave frequencies ranging from between 300 MHz (1.24 μeV) to 300 GHz (1.24 meV), which are sufficiently low enough in energy that they do not chemically change the substances by ionization. These energies affect the rotational and bi-rotational energies of molecules when absorbed by such species. These absorbances are unique to each type of bending transition, rotation transition and bi-rotational transition; hence, energies may be selected that interact specifically with each transition. This property allows the ability to select the desired microwave frequency to interact with a specific reactant in a flow cell reactor, which allows several capabilities.
For example, this allows temperature limitations associated with the boiling point of solids to be overcome. By selectively activating only the precursors associated with the synthesis of nanoparticles, the solvent selection can be increased significantly to allow for the solubility of precursors that would not normally be used. Additionally, temperatures of the precursors can effectively be much greater than the solvent, thereby allowing for reactions that are not allowed through traditional heating of the solvent.
The tube 40 carrying the precursors 32, 34 through the energy source 50 can be configured with a cooling system, such as tubes that encircle the tube and carry cooling liquid. This allows the precursors within the tube to be heated, by microwaves or the like, to high enough energy levels to promote nucleation without overheating the tube itself and compromising its structural limits.
Also, nanoparticles may be formed that are not feasible using traditional colloidal nanoparticle synthetic techniques. For example, the energy required for the formation of GaN nanoparticles is great enough to surpass the boiling point of any solvent that is available for synthetic techniques. Accordingly, the formation of these nanoparticles is only done through high energy intensive and expensive deposition systems such as Atomic Layer Deposition (“ALD”). This is done because only the precursors needed for the formation of the GaN nanoparticles are heated in the microwave initiated reaction of the present invention.
Moreover, in cases where one or more reaction pathways are possible, the selective application of microwave frequencies allows for the activation of a desirable reaction pathway. For example, if a given reaction is thermodynamically dominated, the use of selective microwave activating allows for the formation of the kinetic product. The ability to selectively target which species the reaction is going to absorb the microwave energy extends the ability of the continuous flow cell reactor to deliver products that would not normally be delivered at a cost that the microwave continuous flow cell reactor is capable of delivering.
Another example of a possible benefit with selective frequency microwaving involves the use of a polyol process to synthesize nanoparticles of metallic salts. In this process, the metallic (Ni, Co, Ag, and mixtures thereof) salts (acetate, chloride, fluoride, nitrate) are dissolved at 1.0-3.0 mmol ethylene glycol or polypropylene glycol (or similar polyol). At 2.45 GHz, the solvent absorbs the microwave irradiation very strongly, heating the solvent to the point where it then acts as the reducing agent for the metallic precursor, allowing for the formation of metallic nanoparticles. These types of reactions can be shown symbolically as noted below:
Ni(O2CCH3)2+propylene glycol→Ni(0) nanoparticles
AgNO3+ethylene glycol→Ag(0) nanoparticles
Another example is the microwave absorption of precursors for the synthesis of PbS nanoparticles. The synthesis of PbS may be done in the following manner. 1.5 mmol of lead oleate is dissolved in 1-octadecene with the addition of 3.0 mmol-12.0 mmol of oleic acid. 1.4 mmol of bis(trimethylsilyl)sulfide (TMS2S) which was previously dissolved in the 1-octadecene. The microwave frequency of 2.45 GHz is chosen because both the oleic acid and the 1-octadecene have very low absorption cross-sections at this frequency. On the other hand, both the TMS2S and the lead oleate have a relatively large absorption cross-section at this frequency, allowing the absorption by these materials and the selective activation. This exemplar reaction can be shown symbolically as noted below.
Pb(oleate)2+TMS2S→PbS(oleate) nanoparticles
Zone 3—Growth
This is the growth zone. At this point, the nucleates undergo one of two processes: (1) combination with other nucleates to form nanoparticles/quantum dots of the correct core size, or (2) combination with unreacted precursors to form an epitaxial growth system allowing for the formation of the nanoparticles/quantum dots at a very controlled pace. The material is allowed to remain in the growth zone for a period necessary for them to grow to the specific desired core size, after which, the material is moved through Zone 4.
In general, in the growth phase, the nucleates are preferably heated in a heat source 60 over a longer period of time, such as greater than 100 seconds, at a lower energy level than what they faced during nucleation. This allows thermodynamic growth and Ostwald Ripening. This heating may be done using several different systems, including, but not limited to, sand baths, convection ovens, forced air heating, induction ovens, oil baths and column heaters. Preferably, this heat source 60 is spaced apart from the energy source 50 used in nucleation and is custom-tailored to provide optimal growth of the nucleates. The length of the flow path tube 40 extending through the heat source, diameter of the tube, temperature of the heat source, uniform distribution of heat within the tube, and nucleate flow rate though the heat source are selected to optimize growth of the nucleates during this phase (as shown in
Referring to
Zone 4—Quenching
The flow path continues past zone 3 to zone 4, where the reaction is immediately terminated through a temperature reduction using a quenching system 86 such as a quenching bath or the like. After quenching the growth of the nanoparticle 70, the segmentation is removed through a degassing step 150 (
If needed, increasing the pressure in the flow path 22 can increase the boiling point of a solvent used in the process, thereby allowing the system to operate at higher temperatures and energy levels. One possible way to increase the pressure in the flow path involves inserting a restrictive flow valve into the flow path downstream of the quenching stage. The flow through the valve can be adjusted so as to increase the pressure in the tube upstream of the valve, thereby increasing the pressure in the tube through zones 2 and 3, where the precursor and nucleates are activated and grown.
Preferably and as best shown in
Real-Time Quality Testing and System Optimization
As shown in
The testing structure can be in communication with a control system 80 that monitors the results from the testing system 72 and can modulate, preferably in real-time, components in zones 1-4 as needed to optimize the quality of the nanoparticles produced. For example, the flow of the individual precursors, the time and temperature-heating-excitation energy applied through zone 2 and 3 and the amount of reactively inert gas segmented into the flow path in zone 1 can be adjusted by the control system as needed to optimize detected quality of the nanoparticles produced.
Depending on how many shells are introduced onto the surface of the core material (which is produced in Zones 1-4), Zones 1, 3 and 4 can be repeated using a different set of materials (precursors/components) to form core/shell, core/shell/shell and core/shell/shell/shell type structures.
Shell Fabrication System
A post-production shell application system 100 may be provided following the production of the nanoparticles as shown in
The purpose for the shell architecture surrounding the core nanoparticle material is two-fold. First, by matching the lattice parameters closely of the core material, a first shell can be added which increases the quantum yield of the resultant nanoparticle upon exposure to light. This is done by passivating the nanoparticle core surface and eliminating dangling bonds which contribute to non-radiative recombination events. Also, by lattice matching the materials of the nanoparticle core and the first shell, strain effects are reduced, which also causes an increase in the quantum yield of the resultant nanoparticle.
This first shell may also have the added benefit of providing a barrier against environmental degradation effects, such as photo-bleaching and/or oxidation of the core material, which will result in either a blue-shifting of emitted light, or provide multiple trap sites for reduction of effective and desirable electronic properties. However, in the event that this is not provided by the first shell, a second and/or third shell may be provided that will enhance the operational lifetime of nanoparticle materials when used in applications. These second and third shells do not necessarily have to be lattice matched to enhance optical properties unless they interact with the wave function associated with the nanoparticle in the excited state. The primary purpose of the second and third shell are to provide increased operational lifetime by providing protection to the nanoparticle core/shell from environmental effects, which include, but are not limited to: oxidation, photobleaching and temperature extremes.
The first shell integrity can be verified by measuring the quantum yield of the nanoparticle after the first shell has been placed onto the core of the nanoparticle. Poor coverage by the first shell, or poor lattice matching by the first shell will result in low quantum yields (<50%), whereas good coverage by the first shell and good lattice matching between the first shell and the core material will result in large quantum yields (>50%).
The lifetime of the materials can be evaluated by exposure to light, preferably between 250 nm and 700 nm, and measuring the photoluminescent response as a function of time. Increased operational lifetime and enhancement of the stability of these nanoparticles by inclusion of a second and, perhaps, a third shell, will show less than 5% photodegration of a 10 wt % material in solvent exposed to a minimum of 5 mW light source over the period of two weeks upon continuous exposure in standard atmospheric conditions.
System Redundancy and Redirectable Flow Paths
As shown in
Conservation of Excess Microwave Energy
As shown schematically in
The microwave energy entering the growth chamber can be controlled through an insertable and movable baffle 310 which can attenuate the amount of microwave energy entering the growth area heating source. The temperature of the growth area heating source can be monitored by the control system 72 which modulates the baffle position as needed to maintain a desired temperature in the growth chamber.
Exemplar precursor combinations that have may work particularly well in this flow cell reactor include first precursors selected from those found in “Group A” below with the second precursor is selected from “Group B” or “Group C” below using conventional periodic table nomenclature.
Group A—Precursors
H2X
R3P=X
R3N=X
((CH3)3Si)2X
(((CH3)3Si)2N)2X
H—X—(CH2)n—CH3
HO—CH2—(CH(OH))n—CH3
HO—CH2—(CH(OH))n—CH2—OH
H2NNH2
NaBH4
NaCNBH3
and mixtures thereof
including anionic precursors and/or reducing agents
Group B—Precursors
M(ligand)y
Or mixtures thereof.
Group C—Precursors
M(ligand)y
or mixtures thereof.
The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.
Schut, David M., Williams, George M., Novet, Thomas E.
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