Air controlled electrospray manufacturing and products thereof

Patent metadata

Field	Value
Publication number	US-2018369839-A1
Application number	US-201615775732-A
Country	US
Kind code	A1
Filing date	Nov 10, 2016
Priority date	Nov 12, 2015
Publication date	Dec 27, 2018
Grant date	—

Abstract

Provided in certain embodiments herein are gas controlled electrospray systems and processes for manufacturing depositions, such as thin layer films. In some embodiments, processes and systems provided herein are suitable for and configured to manufacture uniform depositions, such as having uniform thickness.

First claim

1 .- 42 . (canceled)

43 . A process for producing a graphenic film, the process comprising producing an aerosol or plume from a fluid stock,
the fluid stock comprising a fluid and a graphenic component, the graphenic component comprising graphene, graphene oxide, or reduced graphene oxide, the aerosol or plume being produced by (i) providing the fluid stock to a first inlet of a first conduit of an electrospray nozzle, the first conduit being enclosed along the length of the first conduit by a wall having an interior surface and an exterior surface, the first conduit having a first outlet, and (ii) providing a voltage to the nozzle, and the aerosol or plume being produced in the presence of a high velocity gas, the high velocity gas having a velocity of at least 0.5 m/s, and the film having a thickness of less than 1 mm.

44 . The process of claim 1 , wherein the high velocity gas at least partially surrounds a fluid stock jet ejected from the first outlet of the electrospray nozzle.

45 . The process of claim 1 , wherein the film has a thickness of 50 nm to 1 mm.

46 . The process of claim 1 , wherein the film has a thickness variation of less than 50% of the average thickness.

47 . The process of claim 4 , wherein the film has a thickness variation of less than 10% of the average thickness.

48 . The process of claim 1 , wherein the fluid stock further comprises a plurality of nanoparticles.

49 . The process of claim 1 , wherein the graphenic component comprises graphene, graphene oxide, reduced graphene oxide, or any combination thereof.

50 . The process of claim 1 , wherein the fluid comprises water, an alcohol, dimethylformamide (DMF), tetrahydrofuran (THF), Dimethylacetamide (DMAc), chloroform, dichloromethane, or N-methyl-pyrrolidone (NMP).

51 . The process of claim 1 , wherein the graphenic component is present in the fluid stock in a concentration of at least 0.5 wt. %.

52 . The process of claim 9 , wherein the graphenic component is present in the fluid stock in a concentration of at least 1 wt. %.

53 . The process of claim 1 , wherein the graphenic component is present in the fluid stock in a concentration of at least 10 wt. %.

54 . The process of claim 1 , wherein the voltage applied to the nozzle is 8 kV to 60 kV.

55 . The process of claim 14 , wherein the fluid stock is provided to the first inlet at a rate of at least 0.1 mL/min.

56 . The process of claim 1 , wherein the viscosity of the fluid stock is at least 20 cP.

57 . The process of claim 14 , wherein the viscosity of the fluid stock is at least 200 cP.

58 . The process of claim 1 , wherein the graphenic film is collected on a roll-to-roll assembly platform.

59 . A system for manufacturing a film, the system comprising:
a. a nozzle comprising:
i. a first conduit, the first conduit being enclosed along the length of the conduit by a wall having an interior surface and an exterior surface, the first conduit having a first inlet end and a first outlet end, and the first conduit having a first diameter; and
ii. a second conduit, the second conduit being enclosed along the length of the conduit by a second wall having an interior surface, the second conduit having a second inlet end and a second outlet end, and the second conduit having a second diameter;
b. a power supply configured to apply a voltage to the wall of the first conduit; c. a collector configured to receive a (non-fibrous) deposition thereon, the collector being grounded, or being configured between a ground and the nozzle; d. a pressurized gas supply configured to provide a high velocity gas to the second conduit, the high velocity gas having a velocity of at least 0.5 m/s.

60 . A film comprising at least 20% graphene component by weight and having an average thickness of 200 micron or less, and having a thickness variation of less than 50% of the average thickness thereof.

61 . The film of claim 18 , wherein the film comprises at least 40% graphene component by weight.

62 . The film of claim 19 , wherein the film comprises at least 90% graphene component by weight.

Assignees

• Univ Cornell

Inventors

• Joo Yong Lak
• Zhmayev Yevgen

Classifications

• C09D7/67

  Particle size smaller than 100 nm · CPC title

• C09D129/04

  Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids · CPC title

• B05D1/06

  Applying particulate materials · CPC title

• C08L101/00

  Compositions of unspecified macromolecular compounds · CPC title

• B05D3/042

  Directing or stopping the fluid to be coated with air · CPC title