Seedless particles with carbon allotropes

Patent metadata

Field	Value
Publication number	US-2018294142-A1
Application number	US-201816003680-A
Country	US
Kind code	A1
Filing date	Jun 8, 2018
Priority date	Feb 9, 2017
Publication date	Oct 11, 2018
Grant date	—

Abstract

Carbon materials having carbon aggregates, where the aggregates include carbon nanoparticles and no seed particles, are disclosed. In various embodiments, the nanoparticles include graphene, optionally with multi-walled spherical fullerenes and/or another carbon allotrope. In various embodiments, the nanoparticles and aggregates have different combinations of: a Raman spectrum with a 2D-mode peak and a G-mode peak, and a 2D/G intensity ratio greater than 0.5, a low concentration of elemental impurities, a high Brunauer-Emmett and Teller (BET) surface area, a large particle size, and/or a high electrical conductivity. Methods are provided to produce the carbon materials.

First claim

What is claimed is:

1 . A carbon material comprising:
a plurality of carbon aggregates, each carbon aggregate comprising a plurality of carbon nanoparticles, each carbon nanoparticle comprising graphene, with no seed particles; wherein:
the graphene in the plurality of carbon nanoparticles comprises up to 15 layers;
a median size of the carbon aggregates that comprise the carbon nanoparticles is from 1 micron to 50 microns;
a surface area of the carbon aggregates is at least 50 m 2 /g, when measured via a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate; and
the carbon aggregates, when compressed, have an electrical conductivity at least 500 S/m.

2 . The carbon material of claim 1 , wherein the surface area of the carbon aggregates is from 50 m 2 /g to 300 m 2 /g, when measured via a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate.

3 . The carbon material of claim 1 , wherein the carbon aggregates, when compressed, have an electrical conductivity from 500 S/m to 20,000 S/m.

4 . The carbon material of claim 1 , further comprising one or more other carbon allotropes in addition to graphene, wherein a percentage of the graphene to the other carbon allotropes is greater than 90%.

5 . The carbon material of claim 1 , wherein a Raman spectrum of the carbon material, using 532 nm incident light, comprises: a 2D-mode peak; a G-mode peak; and a 2D/G intensity ratio greater than 0.5.

6 . The carbon material of claim 1 , further comprising amorphous carbon, wherein:
a percentage of the amorphous carbon to the graphene is less than 5%; and a Raman spectrum of the carbon material comprising the amorphous carbon, using 532 nm incident light, comprises: a 2D-mode peak; a D-mode peak; a G-mode peak; a D/G intensity ratio greater than 0.5; a low intensity 2D-mode peak; and a shallow valley between the D-mode peak and G-mode peak.

7 . The carbon material of claim 1 , wherein the carbon aggregates are post-processed using a method selected from the group consisting of milling, grinding, exfoliating, annealing, sintering, steaming, filtering, lypolizing, doping, and adding elements.

8 . The carbon material of claim 7 , wherein the surface area of the post-processed carbon aggregates is from 50 m 2 /g to 1000 m 2 /g, when measured using the BET method with nitrogen as the adsorbate.

9 . The carbon material of claim 1 , wherein the graphene has a 3D structure.

10 . An electrically conductive ink comprising the carbon material of claim 1 and liquids.

11 . A tire additive comprising the carbon material of claim 1 .

12 . A battery electrode comprising the carbon material of claim 1 .

13 . A carbon material comprising:
a plurality of carbon aggregates, each carbon aggregate comprising a plurality of carbon nanoparticles, each carbon nanoparticle comprising graphene and multi-walled spherical fullerenes, with no seed particles; wherein:
the graphene in the plurality of carbon nanoparticles comprises up to 15 layers;
a Raman spectrum of the carbon material comprising the multi-walled spherical fullerenes, using 532 nm incident light, comprises: a D-mode peak; a G-mode peak; and a D/G intensity ratio less than 1.2; a median size of the carbon aggregates that comprise the carbon nanoparticles is from 1 micron to 100 microns; a surface area of the carbon aggregates is at least 10 m 2 /g, when measured using a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate; and the carbon aggregates, when compressed, have an electrical conductivity at least 500 S/m.

14 . The carbon material of claim 13 , a surface area of the carbon aggregates is from 10 m 2 /g to 300 m 2 /g, when measured using a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate.

15 . The carbon material of claim 13 , wherein the carbon aggregates, when compressed, have an electrical conductivity from 500 S/m to 20,000 S/m.

16 . The carbon material of claim 13 , wherein the D/G intensity ratio is from 0.9 to 1.1.

17 . The carbon material of claim 13 , wherein a percentage of the multi-walled spherical fullerenes to the graphene is from 20% to 80%.

18 . The carbon material of claim 13 , wherein the multi-walled spherical fullerenes comprise connected multi-walled spherical fullerenes, in which at least some of the multi-walled spherical fullerenes are coated by layers of the graphene.

19 . The carbon material of claim 13 , wherein the carbon aggregates are post-processed using a method selected from the group consisting of milling, grinding, exfoliating, annealing, sintering, steaming, filtering, lypolizing, doping, and adding elements.

20 . The carbon material of claim 19 , wherein the surface area of the post-processed carbon aggregates is from 50 m 2 /g to 500 m 2 /g, when measured using the BET method with nitrogen as the adsorbate.

21 . The carbon material of claim 13 , wherein the graphene has a 3D structure.

22 . A carbon material comprising:
a plurality of carbon aggregates, each carbon aggregate comprising a plurality of carbon nanoparticles, each carbon nanoparticle comprising a mixture of graphene and at least one other carbon allotrope, with no seed particles; wherein:
the graphene in the plurality of carbon nanoparticles comprises up to 15 layers;
a median size of the carbon aggregates that comprise the carbon nanoparticles is from 1 micron to 100 microns;
a surface area of the carbon aggregates is at least 10 m 2 /g, when measured using a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate; and
the carbon aggregates, when compressed, have an electrical conductivity at least 100 S/m.

23 . The carbon material of claim 22 , wherein a surface area of the carbon aggregates is from 10 m 2 /g to 300 m 2 /g, when measured using a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate.

24 . The carbon material of claim 22 , wherein the carbon aggregates, when compressed, have an electrical conductivity from 500 S/m to 20,000 S/m.

25 . The carbon material of claim 22 , wherein a percentage of the graphene to the at least one other carbon allotrope is from 5% to 95%.

26 . The carbon material of claim 22 , wherein a Raman spectrum of the carbon material comprising the graphene, using 532 nm incident light, comprises: a 2D-mode peak; a G-mode peak; and a 2D/G intensity ratio greater than 0.5.

27 . The carbon material of claim 22 , wherein the at least one other carbon allotrope comprises multi-walled spherical fullerenes.

28 . The carbon material of claim 27 , wherein a percentage of the graphene to the multi-walled spherical fullerenes is from 20% to 80%.

29 . The carbon material of claim 27 , wherein the multi-walled spherical fullerenes comprise connected multi-walled spherical fullerenes, in which at least some of the multi-walled spherical fullerenes are coated by layers of the graphene.

30 . The carbon material of claim 22 , wherein the at least one other carbon allotrope comprises amorphous carbon.

31 . The carbon material of claim 30 , wherein a percentage of the graphene to the amorphous carbon is greater than 95%.

32 . The carbon material of claim 22 , wherein the at least one other carbon allotrope comprises predominantly sp 3 hybridization.

Assignees

• Lyten Inc

Inventors

• Anzelmo Bryce H
• Cook Daniel
• Ghezelbash Hossein-Ali
• Singh Shreeyukta
• Stowell Michael W
• Tanner David

Classifications

• H01J37/32192 Primary

  Microwave generated discharge (H01J37/32357, H01J37/32366, H01J37/32394, H01J37/32403 take precedence) · CPC title

• C01B32/00 Primary

  Carbon; Compounds thereof (C01B21/00, C01B23/00 take precedence; percarbonates C01B15/10; carbon black C09C1/48) · CPC title

• C01B32/19

  by exfoliation · CPC title

• H01J2237/334

  Etching · CPC title

• H01J37/32532

  Electrodes · CPC title