Production of monodisperse cerium oxide microspheres with diameters near 100 µm by internal-gelation sol–gel methods

Internal-gelation sol–gel methods have used a variety of sphere-forming methods in the past to produce metal oxide microspheres, but typically with poor control over the size uniformity at diameters near 100 µm. This work describes efforts to make and measure internal-gelation, sol–gel microspheres with very uniform diameters in the 100–200-µm size range using a two-fluid nozzle. A custom apparatus was used to form aqueous droplets of sol–gel feed solutions in silicone oil and heat them to cause gelation of the spheres. Gelled spheres were washed, dried, and sintered prior to mounting them on glass slides for optical imaging and analysis. Microsphere diameters and shape factors were determined as a function of silicone oil flow rate in a two-fluid nozzle and the size of a needle dispensing the aqueous sol–gel solution. Nine batches of microspheres were analyzed and had diameters ranging from 65.5 ± 2.4 µm for the smallest needle and the fastest silicone oil flow rate to 211 ± 4.7 µm for the largest needle and the slowest silicone oil flow rate. Standard deviations for measured diameters were less than 8% for all samples and most of them were less than 4%. Microspheres had excellent circularity with measured shape factors of 0.9–1. However, processing of optical images was complicated by shadow effects in the photoresist layer on glass slides and by overlapping microspheres. Based on the calculated flow parameters, microspheres were produced in a simple dripping mode in the two-fluid nozzle. Using flow rates consistent with a simple dripping mode in a two-fluid nozzle configuration allows for very uniform oxide microspheres to be produced using the internal-gelation sol–gel method.