Carbon disposed at interstitial sites of a polymer matrix

Patent metadata

Field	Value
Publication number	US-12371773-B2
Application number	US-202418670583-A
Country	US
Kind code	B2
Filing date	May 21, 2024
Priority date	Aug 2, 2018
Publication date	Jul 29, 2025
Grant date	Jul 29, 2025

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 the one or more particles independently comprise a polymer matrix having graphene disposed in interstitial sites of the polymer matrix.

2. The composition of matter as recited in claim 1 , wherein at least some of the graphene is characterized by having a structure comprising one or more coherent, planar layers.

3. The composition of matter as recited in claim 1 , wherein at least some of the graphene is interlaced interstitially between basal planes of the polymer matrix.

4. The composition of matter as recited in claim 1 , wherein the graphene is substantially devoid of crystallographic defects.

5. The composition of matter as recited in claim 1 , wherein the one or more particles are characterized by a lack of carbon aggregate(s) and/or carbon agglomerate(s) at grain boundaries thereof.

6. 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; and
wherein the polymer matrix comprises from about 15 wt % to about 60 wt % of the carbon disposed in the interstitial sites thereof.

7. The composition of matter as recited in claim 1 , wherein at least some of the graphene is pristine.

8. A composition of matter, comprising one or more particles, wherein the one or more particles independently comprise a polymer matrix having carbon disposed in interstitial sites of the polymer matrix.

9. The composition of matter as recited in claim 8 , wherein at least some of the carbon is characterized by having a structure comprising one or more coherent, planar layers.

10. The composition of matter as recited in claim 8 , wherein at least some of the carbon is interlaced interstitially between basal planes of the polymer matrix.

11. The composition of matter as recited in claim 8 , wherein the carbon is substantially devoid of crystallographic defects.

12. The composition of matter as recited in claim 8 , wherein the one or more particles are characterized by a lack of carbon aggregate(s) and/or carbon agglomerate(s) at grain boundaries thereof.

13. The composition of matter as recited in claim 8 , wherein the one or more particles independently comprise from about 15 wt % carbon to about 90 wt % carbon; and
wherein the polymer matrix comprises from about 15 wt % to about 60 wt % of the carbon disposed in the interstitial sites thereof.

14. A composition of matter, comprising a polymer matrix having at least about 6 wt % carbon disposed in the polymer matrix, wherein at least some of the carbon is disposed at interstitial sites of the polymer matrix.

15. The composition of matter as recited in claim 14 , wherein grain boundaries of the composition of matter are substantially devoid of carbon aggregate(s) and/or agglomerate(s).

16. The composition of matter as recited in claim 14 , wherein at least some carbon atoms are covalently bonded to other carbon atoms disposed in the polymer matrix.

17. The composition of matter as recited in claim 16 , wherein the covalent bonds between the carbon atoms comprise non-polar covalent bonds.

18. The composition of matter as recited in claim 14 , wherein the carbon is substantially homogeneously distributed throughout the polymer matrix.

19. The composition of matter as recited in claim 14 , wherein a largest discernable feature size of the composition of matter is in a range from about 0.1 nm to about 1 μm.

20. An electrochemical cell comprising the composition of matter as recited in claim 1 .

21. The electrochemical cell as recited in claim 20 , wherein the electrochemical cell is characterized by a coin configuration.

22. The electrochemical cell as recited in claim 20 , wherein the electrochemical cell is characterized by a cylindrical configuration.

23. The electrochemical cell as recited in claim 20 , wherein the electrochemical cell is characterized by a prismatic configuration.

24. The electrochemical cell as recited in claim 20 , wherein the electrochemical cell is characterized by a pouch configuration.

25. The electrochemical cell as recited in claim 20 , wherein the electrochemical cell neither includes nor is coupled to any distinct structure serving as a current collector other than an electrode.

26. An electrochemical cell comprising the composition of matter as recited in claim 8 .

27. The electrochemical cell as recited in claim 26 , wherein the electrochemical cell is characterized by a coin configuration.

28. The electrochemical cell as recited in claim 26 , wherein the electrochemical cell is characterized by a cylindrical configuration.

29. The electrochemical cell as recited in claim 26 , wherein the electrochemical cell is characterized by a prismatic configuration.

30. The electrochemical cell as recited in claim 26 , wherein the electrochemical cell is characterized by a pouch configuration.

31. The electrochemical cell as recited in claim 26 , wherein the electrochemical cell neither includes nor is coupled to any distinct structure serving as a current collector other than an electrode.

32. An electrochemical cell comprising the composition of matter as recited in claim 14 .

33. The electrochemical cell as recited in claim 32 , wherein the electrochemical cell is characterized by a coin configuration.

34. The electrochemical cell as recited in claim 32 , wherein the electrochemical cell is characterized by a cylindrical configuration.

35. The electrochemical cell as recited in claim 32 , wherein the electrochemical cell is characterized by a prismatic configuration.

36. The electrochemical cell as recited in claim 32 , wherein the electrochemical cell is characterized by a pouch configuration.

37. The electrochemical cell as recited in claim 32 , wherein the electrochemical cell neither includes nor is coupled to any distinct structure serving as a current collector other than an electrode.

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