Method of forming particles comprising carbon and articles therefrom

Patent metadata

Field	Value
Publication number	US-2016185606-A9
Application number	US-201113316094-A
Country	US
Kind code	A9
Filing date	Dec 9, 2011
Priority date	Apr 14, 2010
Publication date	Jun 30, 2016
Grant date	—

Abstract

A method of growing carbonaceous particles comprises depositing carbon from a carbon source, onto a particle nucleus, the particle nucleus being a carbon-containing material, an inorganic material, or a combination comprising at least one of the foregoing, and the carbon source comprising a saturated or unsaturated compound of C 20 or less, the carbonaceous particles having a uniform particle size and particle size distribution. The method is useful for preparing polycrystalline diamond compacts (PDCs) by a high-pressure, high temperature (HPHT) process.

First claim

1 . A method of growing carbonaceous particles, comprising:
depositing carbon from a carbon source, onto a particle nucleus, the particle nucleus being a carbon-containing material, an inorganic material, or a combination comprising at least one of the foregoing, and the carbon source comprising a saturated or unsaturated compound of C 20 or less, the carbonaceous particles having a uniform particle size and particle size distribution.

2 . The method of claim 1 , wherein the particle nucleus is derivatized, underivatized, or a combination of derivatized and underivatized, and comprises diamond, diamond-like carbon, carbon black, graphite, graphene, nanotubes, or a combination comprising at least one of the foregoing.

3 . The method of claim 2 , wherein the diamond is a nanodiamond, microdiamond, or a combination comprising at least one of the foregoing

4 . The method of claim 2 , wherein the nanotubes are carbon nanotubes, inorganic nanotubes, metallated nanotubes, or a combination comprising at least one of the foregoing.

5 . The method of claim 1 , wherein the nanotubes are single walled nanotubes, multiwalled nanotubes, or a combination comprising at least one of the foregoing.

6 . The method of claim 1 , wherein the nanoparticle has a number averaged particle size of less than or equal to about 1,000 micrometers.

7 . The method of claim 6 , wherein the nanoparticle has a number averaged particle size of about 1 to less than about 1,000 nanometers.

8 . The method of claim 6 , wherein the nanoparticle has a number averaged particle size of about 1 to about 1,000 micrometers.

9 . The method of claim 1 , wherein the nanoparticle is monodisperse or polydisperse in particle size distribution.

10 . The method of claim 1 , wherein the carbon source comprises a saturated or unsaturated C 1-4 carbon molecule.

11 . The method of claim 10 , wherein the carbon source comprises methane, ethylene, acetylene, or a combination comprising at least one of the foregoing compounds.

12 . The method of claim 1 , wherein the carbon source comprises an organometallic complex.

13 . The method of claim 12 , wherein the carbon source is a metallocene.

14 . The method of claim 1 , wherein treating comprises chemical vapor deposition, pyrolysis, or a combination comprising at least one of the foregoing.

15 . The method of claim 1 , wherein the nanoparticle comprises a spherical shape, worm-like carbon structure, a carbon nanofiber, a carbon nano and/or micro-coil, or a combination comprising at least one of the foregoing.

16 . The method of claim 1 , wherein depositing is further carried out in the presence of hydrogen, an inert gas, or a combination comprising the foregoing.

17 . The method of claim 1 , wherein diamond is formed by the depositing.

18 . A method of forming an article, comprising:
depositing carbon from a carbon source, onto
a particle nucleus comprising a carbon-containing material, an inorganic material, or a combination comprising at least one of the foregoing, the carbon source comprising a saturated or unsaturated C 1-4 compound, and
forming an article from the particle formed by depositing carbon onto the particle nucleus, by casting, heating, pressurizing, molding, or a combination comprising at least one of the foregoing steps, the particle so formed by treating having a uniform particle size and particle size distribution.

19 . A method of forming a polycrystalline diamond compact, comprising
heating and pressure treating, in the presence of a metal catalyst, a diamond table comprising nanodiamonds, microdiamonds, or a combination comprising at least one of the foregoing,
the nanodiamonds and/or microdiamonds being formed by depositing carbon from a carbon source onto a particle nucleus comprising a carbon-containing material, an inorganic material, or a combination comprising at least one of the foregoing, the carbon source comprising a saturated or unsaturated compound of C 20 or less,
the nanodiamonds and/or microdiamonds so formed by depositing having a uniform particle size and particle size distribution.

20 . The method of claim 19 , wherein heating is carried out at a temperature of greater than or equal to about 1,000° C. and pressure treating is carried out at a pressure of greater than or equal to about 5.0 gigapascals.

Assignees

• Mazyar Oleg A
• Chakraborty Soma
• Kuznetsov Oleksandr
• Digiovanni Anthony A
• Agrawal Gaurav
• Johnson Michael H
• Baker Hughes Inc

Inventors

• Mazyar Oleg A
• Chakraborty Soma
• Kuznetsov Oleksandr
• Digiovanni Anthony A
• Agrawal Gaurav
• Johnson Michael H

Classifications

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• C01P2004/51

  Particles with a specific particle size distribution · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title

• B01J2203/0655

  Diamond · CPC title

• C23C16/4417

  Methods specially adapted for coating powder · CPC title