This invention relates generally to a method for controlling the pore size,
pore size distribution and porosity of aluminum-oxide based ceramics through the
choice of substituents on carboxylate-alumoxanes and aluminum-oxide nanoparticles.
The method allows for the formation of intra-granular pores in the nanometer range
to be created in alumina and aluminum oxide ceramic bodies. The control over pore
size and pore size distribution is accomplished through the use of different chemical
substituents on the carboxylate-alumoxanes and aluminum-oxide nanoparticles. The
size and distribution of pores within the alumina-oxide ceramic are dependent on
the identity of the carboxylate substituents. In particular the formation of intra-versus
inter-granular porosity is dependent on the identity of the carboxylate substituents.
The invention also provides methods for the manufacture of ceramic coatings on
ceramic and carbon fibers for composite applications and ceramic membranes with
nanometer sized pores. The pore size, pore size distribution and porosity, and
hence the strength, permeability and surface adhesion, of the ceramic coating is
controlled by the choice of substituent on the carboxylate-alumoxane. Thermolysis
of self supporting spun layers of the carboxylate-alumoxanes results in disks of
alumina with controlled pore size, pore size distribution and porosity. In an alternative
method a porous substrate is dipped or coated with a solution of the carboxylate-alumoxane,
followed by thermolysis to produce a composite membrane.