Coherent or pristine graphene in a polymer matrix

Patent metadata

Field	Value
Publication number	US-12018383-B2
Application number	US-202318367967-A
Country	US
Kind code	B2
Filing date	Sep 13, 2023
Priority date	Aug 2, 2018
Publication date	Jun 25, 2024
Grant date	Jun 25, 2024

Abstract

Inventive techniques for forming unique compositions of matter are disclosed, as well as various advantageous physical characteristics, and associated properties of the resultant materials. In particular, particles comprising polymer matrices are characterized by having carbon disposed within the polymer matrix structure thereof. The carbon is primarily, or entirely, present at interstitial sites of the polymer matrix, and may be present in amounts ranging from about 15 wt % to about 90 wt %. The carbon, moreover, forms covalent bonds with both atoms of the polymer matrix and other carbon atoms present in, but not part of, the matrix. This facilitates substantially homogeneous dispersal of the carbon throughout the resultant material, conveying unique and advantageous properties such as strength-to-weight ratio, density, mechanical toughness, sheer strength, flex strength, hardness, anti-corrosiveness, electrical and/or thermal conductivity, etc. as described herein. In some approaches, the resultant materials may be powderized or pelletized.

First claim

What is claimed is:

1. A composition of matter, comprising one or more particles, wherein some or all of the particles independently comprise a polymer matrix having one or more coherent, planar layers of graphene disposed in the polymer matrix.

2. The composition of matter as recited in claim 1 , wherein at least some carbon atoms of the one or more coherent, planar layers of graphene are disposed in interstitial sites within the polymer matrix.

3. The composition of matter as recited in claim 1 , wherein the one or more coherent, planar layers of graphene are interlaced interstitially between basal planes of the polymer matrix.

4. The composition of matter as recited in claim 1 , wherein the polymer matrix comprises one or more polymeric components or one or more polymeric precursors.

5. The composition of matter as recited in claim 4 , wherein the one or more polymeric components are selected from: thermoplastic olefin(s), thermoplastic polyolefin(s), olefinic thermoplastic elastomer-type structure(s), thermoplastic polymers, photopolymers, liquid crystal polymers, crosslinking polymers, acrylics, copolymers, hybridized crosslinking polymers, epoxies, silicones, acrylic polyols, aliphatic polyisocyanates, urethane acrylates, vinyl alcohols, vinyl halides, acrylamides, diaxonimum salt(s), diaryliodionium salt(s), triarylsulfonium salt(s), alkylsulfonium salt(s), iron arene salt(s), sulfolyloxyketone(s), triarylsiloxysiloxane(s), and combinations thereof; and
wherein the one or more polymeric precursors are precursors of one or more of the polymeric components.

6. The composition of matter as recited in claim 4 , wherein the one or more polymeric components are independently selected from polytrimethylene terephthalate, polyethersulfone, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polythene, polyvinyl halides, polyvinyl alcohols, polytetrafluoroethylene (TEFLON®), polyacrylates, polymethacrylates, polyesters, polyvinylchloride, fluoropolymers, polyamides, polyamide-imides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers, epoxies, alkyds, melamines, phenolics, ureas, vinyl esters, etc.; epoxies, cyanate esters, polyurethanes, acrylonitric butadiene styrene (ABS) and polyacrylonitrile (PAN), ethylene vinyl alcohol, poly(methyl methacrylate) (PMMA), polyvinyl cinnamate, polyisoprene, polyamides, polyimides, styrenic block copolymers, bitumen, nitrile rubber, polycarbonate, polyetherimide (PEI), poly(pheylene sulfide) (PPS), polyetheretherketone (PEEK), polyetherketones (PEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polylactic acid (PLA), polybenzimidazole (PBI), polyetherimide (PEI), polyethersulfone (PES), polyphenylene sulfide (PPS), polyphthalamide (PPA), and combinations thereof.

7. The composition of matter as recited in claim 4 , wherein the one or more polymeric precursors are independently selected from precursors of: polytrimethylene terephthalate, polyethersulfone, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polythene, polyvinyl halides, polyvinyl alcohols, polytetrafluoroethylene (PTFE), polyacrylates, polymethacrylates, polyesters, polyvinylchloride, fluoropolymers, polyamides, polyamide-imides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers, epoxies, alkyds, melamines, phenolics, ureas, vinyl esters, epoxies, cyanate esters, polyurethanes, acrylonitric butadiene styrene (ABS), polyacrylonitrile (PAN), ethylene vinyl alcohol, poly(methyl methacrylate) (PMMA), polyvinyl cinnamate, polyisoprene, polyimides, styrenic block copolymers, bitumen, nitrile rubber, polycarbonate, polyetherimide (PEI), poly(pheylene sulfide) (PPS), polyetheretherketone (PEEK), polyetherketones (PEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polylactic acid (PLA), polybenzimidazole (PBI), polyetherimide (PEI), polyethersulfone (PES), polyphenylene sulfide (PPS), polyphthalamide (PPA), polyamides (6, 11, 6.6, 12, etc.) (PAS), and combinations thereof.

8. The composition of matter as recited in claim 4 , wherein the polymer matrix further comprises one or more additional components selected from: crosslinkers, binders, initiators, terminators, phase-change materials, solvent systems, carbonaceous materials, thermosetting systems, and combinations thereof.

9. The composition of matter as recited in claim 1 , wherein the one or more coherent, planar layers of graphene consist of a single layer of the graphene.

10. The composition of matter as recited in claim 1 , wherein the one or more coherent, planar layers of graphene include at least five layers of the graphene, and no more than fifteen layers of the graphene.

11. The composition of matter as recited in claim 1 , wherein at least some carbon atoms of the one or more layers of graphene are covalently bonded to atoms of the polymer matrix.

12. The composition of matter as recited in claim 11 , wherein the covalent bonds between carbon atoms of the graphene and the atoms of the polymer matrix comprise non-polar covalent bonds.

13. The composition of matter as recited in claim 1 , wherein at least some carbon atoms of the one or more layers of graphene are covalently bonded to other carbon atoms of the one or more layers of graphene.

14. The composition of matter as recited in claim 13 , wherein the covalent bonds between the carbon atoms of the graphene comprise non-polar covalent bonds.

15. The composition of matter as recited in claim 1 , wherein the one or more particles substantially exclude polar covalent bonds.

16. The composition of matter as recited in claim 1 , wherein the polymer matrix of the one or more particles substantially excludes ionic bonds.

17. The composition of matter as recited in claim 1 , wherein the one or more coherent, planar layers of graphene are substantially devoid of defects.

18. The composition of matter as recited in claim 1 , wherein the one or more particles independently comprise from about 15 wt % carbon to about 90 wt % carbon.

19. The composition of matter as recited in claim 1 , wherein the polymer matrix comprises from about 15 wt % to about 60 wt % carbon at interstitial sites thereof.

20. The composition of matter as recited in claim 1 , wherein at least portions of the polymer matrix are characterized by a crystallinity in a range from greater than 0% to about 50%; and
wherein at least some of the graphene bridges at least some crystalline structures of the composition of matter via epitaxy.

21. The composition of matter as recited in claim 1 , wherein each particle is characterized by a lack of carbon aggregate(s) and/or agglomerate(s) at grain boundaries thereof.

22. The composition of matter as recited in claim 1 , wherein each of the one or more particles is characterized by a diameter in a range from about 20 nm to about 3.5 μm.

23. The composition of matter as recited in claim 1 , wherein a largest discernable feature size of the composition of matter is in a range from about 0.1 nm to about 1 μm.

24. The composition of matter as recited in claim 1 , wherein the one or more particles are pressed into a pellet.

Assignees

• Lyten Inc

Inventors

• Anzelmo Bryce H
• Stowell Michael
• Jacobson Daniel
• Sienko Lauren
• Lanning Bruce

Classifications

• Y02E60/10

  Energy storage using batteries · CPC title

• C01B32/182

  Graphene · CPC title

• C08K3/042

  Graphene or derivatives, e.g. graphene oxides · CPC title

• H05H1/461

  Microwave discharges · CPC title

• B22F2202/13

  Use of plasma · CPC title