Direct conversion of teflon tape into diamond, Q-carbon, and graphene films

Patent metadata

Field	Value
Publication number	US-11746016-B2
Application number	US-202117335164-A
Country	US
Kind code	B2
Filing date	Jun 1, 2021
Priority date	Jun 9, 2020
Publication date	Sep 5, 2023
Grant date	Sep 5, 2023

Abstract

In various exemplary embodiments, the present disclosure provides a process for the conversion of certain polymers into diamond and diamond-like materials using laser pulse annealing. The process includes transforming the polymer to carbon, melting the carbon and quenching the carbon melt into to form Q-carbon, diamond, and/or graphene. The process can be applied to a polymer film such as a polytetrafluoroethylene (PTFE) tape. An object can be coated with the polymer film which can then be converted to Q-carbon, diamond, and/or graphene using laser pulse annealing. A process is also provided for making a three-dimensional object using a combination of, for example, 3D printing the polymer and converting each layer of polymer into Q-carbon, diamond and/or graphene.

First claim

What is claimed:

1. A process comprising:
a) increasing absorbance of an unconverted section of a polymer film by at least one conditioning laser pulse to produce a lasered section;
b) melting the lasered section at a temperature of about 4000K by a conversion laser pulse; and
c) quenching the melted lasered section to form an initial quenched section comprising Q-carbon, diamond, and/or graphene,
wherein steps a) through c) occur in an environment at ambient temperature and pressure, and
wherein the polymer film comprises a polymer selected from the group consisting of polyethylene (PE), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polystyrene (PS), and/or polypropylene (PP).

2. The process of claim 1 , wherein the polymer consists of PTFE.

3. The process of claim 1 , wherein the wavelength of the conditioning laser pulse and/or the conversion laser pulse ranges from 193 nm to 308 nm, and wherein the duration of the conditioning laser pulse and/or the conversion laser pulse ranges from 20 ns to 60 ns.

4. The process of claim 1 , wherein the initial quenched section comprises a composite of Q-carbon and diamond.

5. The process of claim 1 , wherein the polymer film is a part of a polytetrafluoroethylene tape.

6. The process of claim 1 , wherein the polymer film is proximate to a substrate, wherein the substrate is selected from the group consisting of metals, semiconductors, ceramics, and glass.

7. The process of claim 6 , wherein the polymer film and the substrate are in a form of a tape.

8. The process of claim 6 , wherein the substrate is an object, and the polymer film is a coating encompassing the object.

9. The process of claim 1 , further comprising:
d) adjusting the polymer film and the at least one quenched section and/or the laser positioning mechanism such that the conditioning laser pulse strikes a subsequent unconverted section of the polymer film;
e) increasing the absorbance of the subsequent unconverted section of the polymer film by the at least one conditioning laser pulse to produce a subsequent lasered section;
f) melting the subsequent lasered section at a temperature of about 4000K by the conversion laser pulse;
g) quenching the melted subsequent lasered section to form a subsequent quenched section comprising Q-carbon, diamond, and/or graphene; and
h) repeating steps d) through g) until a final desired portion of the polymer film is converted to a finished quenched section, wherein the finished quench section comprises the initial quenched section and each of the subsequent quenched sections;
wherein steps e) through g) occur in an environment at ambient temperature and pressure.

10. The process of claim 9 , wherein the finished quenched section is contiguous, and wherein the final desired portion of the polymer film converted to the finished quenched section ranges from 10% to 100%.

11. A process for coating an object comprising:
a) applying a polymer film to at least a portion of the object;
b) increasing the absorbance of an unconverted section of the polymer film by at least one conditioning laser pulse to produce a lasered section;
c) melting the lasered section at a temperature of about 4000K by a conversion laser pulse;
d) quenching the melted lasered section to form an initial quenched section comprising Q-carbon, diamond, and/or graphene;
e) adjusting the object with the applied polymer film and the at least one quenched section and/or the laser positioning mechanism such that the conditioning laser pulse strikes a subsequent unconverted section of the polymer film;
f) increasing the absorbance of the subsequent unconverted section of the polymer film by the at least one conditioning laser pulse to produce a subsequent lasered section;
g) melting the subsequent lasered section at a temperature of about 4000K by the conversion laser pulse;
h) quenching the melted subsequent lasered section to create a subsequent quenched section comprising Q-carbon, diamond, and/or graphene; and
i) repeating steps e) through h) until a final desired portion of the polymer film is converted to the finished quenched section, wherein the finished quenched section comprises the initial quenched section and each of the subsequent quenched sections,
wherein steps b) through d) and steps f) through h) occur in an environment at ambient temperature and pressure, and
wherein the polymer film comprises a polymer selected from the group consisting of polyethylene (PE), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polystyrene (PS), and/or polypropylene (PP).

12. The process of claim 11 , wherein the applying step a) includes 3D printing the polymer film on the object.

13. The process of claim 11 , wherein the wavelength of the conditioning laser pulse and/or the conversion laser pulse ranges from 193 nm to 308 nm, and wherein the duration of the conditioning laser pulse and/or the conversion laser pulse ranges from 20 ns to 60 ns.

14. The process of claim 11 , wherein the object is selected from the group consisting of blades and drill bits.

15. The process of claim 11 , wherein the object is selected from the group consisting of an artificial hip, knee, ankle, wrist, shoulder, and elbow.

16. A process for making a three-dimensional object comprising:
a) applying a first layer of a polymer film on a substrate;
b) increasing the absorbance of an unconverted section of the polymer film by at least one conditioning laser pulse to produce a lasered section;
c) melting the lasered section at a temperature of about 4000K by a conversion laser pulse;
d) quenching the melted lasered section to form an initial quenched section comprising Q-carbon, diamond, and/or graphene;
e) adjusting the polymer film and the at least one quenched section and/or the laser positioning mechanism such that the conditioning laser pulse strikes a subsequent unconverted section of the polymer film;
f) increasing the absorbance of the subsequent unconverted section of the polymer film by the at least one conditioning laser pulse to produce a subsequent lasered section;
g) melting the subsequent lasered section at a temperature of about 4000K by the at least one conversion laser pulse;
h) quenching the melted subsequent lasered section to form a subsequent quenched section comprising Q-carbon, diamond, and/or graphene;
i) repeating steps e) through h) until a final desired portion of the polymer film is converted to a finished quenched section, wherein the finished quenched section comprises the initial quenched section and each of the subsequent quenched sections;
j) applying a subsequent layer of the polymer film in a predetermined pattern to form the three-dimensional object and repeating steps b) through i); and
k) repeating step j) until the three-dimensional object is completed,
wherein steps b) through d) and steps f) through h) occur in an environment at ambient temperature and pressure, and
wherein the polymer film comprises a polymer selected from the group consisting of polyethylene (PE), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), polystyrene (PS), and/or polypropylene (PP).

17. The process of claim 16 , wherein the applying of step a) and/or the applying of step j) includes 3D printing the polymer film.

18. The process of claim 16 , wherein the wavelength of the conditioning laser pulse and/or the conversion laser pulse ranges from 193 nm to 308 nm, and wherein the duration of the conditioning laser pulse and/or the conversion laser pulse ranges from 20 ns to 60 ns.

19. The

Assignees

• Univ North Carolina State

Inventors

• Narayan Jagdish

Classifications

• C01B32/05 Primary

  Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30 · CPC title

• A61F2/3094

  Designing or manufacturing processes · CPC title

• B29C64/188

  involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00) · CPC title

• B29C71/02

  Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)} · CPC title

• B29C71/04

  by wave energy or particle radiation {, e.g. for curing or vulcanising preformed articles (during moulding, e.g. in a mould B29C35/08)} · CPC title