METHOD OF CREATING CARBON MATERIALS

Information

  • Patent Application
  • 20250179657
  • Publication Number
    20250179657
  • Date Filed
    December 05, 2024
    11 months ago
  • Date Published
    June 05, 2025
    5 months ago
  • Inventors
    • Swinehart; Joseph (Rockford, MI, US)
  • Original Assignees
    • Carbon Dragon Technologies LLC (Rockford, MI, US)
Abstract
A method for making carbon materials includes evacuating a reaction chamber, filling the evacuated reaction chamber with a carbon-containing gas, and energizing a plurality of electrodes inside the reaction chamber to create an arc between a first electrode and a second electrode in the presence of the carbon-containing gas.
Description
BACKGROUND

Carbon materials such as graphene and graphene oxide are known for their exceptional properties. Carbon materials can be made using various methods.


SUMMARY

Embodiments disclosed herein can relate to a method for making carbon materials comprising evacuating a reaction chamber, filling the evacuated reaction chamber with a carbon-containing gas, and energizing a first electrode inside the reaction chamber to create an arc between the first electrode and a second electrode in the presence of the carbon containing gas. In some embodiments, the reaction chamber is filled with a carbon-containing gas to a gauge pressure of 0 PSI or greater. In some embodiments, the reaction chamber is filled with a carbon-containing gas at a temperature of about 70 degrees Fahrenheit. In some embodiments, energizing the first electrode comprises applying greater than 10,000 volts DC across the first electrode and the second electrode. In some embodiments, one or more copper substrates are electrically connected to the first electrode. In some embodiments, the method further comprises removing carbon material from the one or more copper substrates after the first electrode is energized.


Embodiments disclosed herein can relate to an apparatus for making carbon materials comprising a body defining a reaction chamber, a lid configured to mate with the body to form a hermetic seal, the lid comprising a port for the passage of fluid and a plurality of electrical terminals, an anode and a cathode positioned inside the reaction chamber, the anode and cathode electrically connected to the plurality of electrical terminals, and a power source electrically connected to the electrical terminals. In some embodiments, the lid comprises a flange configured to mate with a flange on the body. In some embodiments, each flange comprises through holes for receiving bolts to clamp the flanges together. In some embodiments, the power source is configured to provide DC current at 10,000 volts or greater. In some embodiments, the power source comprises a flyback transformer. In some embodiments, the anode comprises tungsten. In some embodiments, the cathode comprises copper. In some embodiments, the apparatus further comprises one or more copper substrates electrically connected to the cathode. In some embodiments, the anode and the cathode are spaced less than or equal to two inches from each other.


Embodiments herein can relate to an apparatus for making carbon materials comprising a cylindrical body defining a reaction chamber, the body having a first flange around an upper opening of the body, a lid having a second flange configured to mate with the first flange to form a hermetic seal, the lid comprising a first hole for the passage of fluid and second hole for the passage of wires, a manifold connected to the first hole, the manifold in fluid communication with first source comprising compressed carbon dioxide and a second source comprising a vacuum pump, an anode and a cathode positioned inside the reaction chamber, the anode and cathode electrically connected to wires passing through the second hole, an electrical power supply for providing electricity to the anode and cathode via the wires, the electrical power supply configured to provide at least 10,000 volts DC, wherein the chamber has a radius of at least 4 inches and a length of at least 12 inches, wherein the anode and cathode are each positioned at least 4 inches from a sidewall of the body, and wherein the anode and cathode are positioned at least 1 mm from each other. In some embodiments, the apparatus further comprises one or more substrates electrically connected to the cathode.





BRIEF DESCRIPTION OF THE DRAWINGS


FIG. 1 depicts an apparatus for making carbon materials in accordance with the embodiments disclosed herein.



FIG. 2 depicts an apparatus for making carbon materials in accordance with the embodiments disclosed herein.



FIG. 3 is a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 4 depicts Raman spectra for a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 5 depicts an apparatus for making carbon materials in accordance with the embodiments disclosed herein.



FIG. 6 is a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 7 depicts Raman spectra for a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 8 is a substrate containing a carbon material created in accordance with the embodiments disclosed herein.



FIG. 9 is a Raman spectrum for a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 10 depicts an electrode configuration of an apparatus for making carbon materials in accordance with the embodiments disclosed herein.



FIG. 11 is a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 12 is a Raman spectrum for a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 13 is a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 14 is a Raman spectrum for a sample carbon material created in accordance with the embodiments disclosed herein.



FIG. 15 depicts an apparatus for making carbon materials in accordance with the embodiments disclosed herein.





DESCRIPTION

Carbon materials include graphene and graphene oxide. Graphene and graphene oxide are carbon materials with significant potential for use in many different industries. Graphene is known for its exceptional mechanical properties (high strength and elasticity), high electrical and thermal conductivity, impermeability to gases, transparency to light, and other favorable properties. Graphene oxide is known for its mechanical strength, high surface area, and chemical properties. Graphene oxide has high oxidation, is hydrophilic and easily dispersible in water, has tunable conductivity, has antimicrobial properties, and other favorable properties. The market for graphene and graphene oxide is impeded by a lack of economical manufacturing capability.


Embodiments disclosed herein for creating carbon materials including graphene and graphene oxide are inexpensive and require lower temperature, pressure, and energy inputs than other methods. Embodiments disclosed herein include systems and methods for creating carbon materials using a carbon-containing gas and electrical current inside a reaction chamber where temperature is monitored and pressure can be controlled. In some embodiments, the carbon-containing gas is carbon dioxide. In some embodiments, the electrical current includes creating an electrical arc from an anode to a cathode. Some embodiments further include the use of hydrogen in the reaction chamber. Some embodiments further include the use of a substrate in the reaction chamber. The results of these systems and methods include carbon products including graphene, graphene oxide, graphite, amorphous carbon, aromatic carbon rings, and other carbon products.



FIG. 1 illustrates an apparatus for producing carbon materials in accordance with the embodiments disclosed herein. The apparatus 100 has a containment vessel 110, which forms a reaction chamber for carrying out the various methods disclosed herein. The containment vessel 110 has a body 120 and a lid 130. The body 120 can be constructed of a material suitable for withstanding high pressure and temperature cycles, such as, for example, stainless steel. Other metals, plastics, silicone, or other suitable materials can be used as well. The body 120 can have a cylindrical shape, or another shape suitable for forming a pressure vessel. For example, the body can be shaped as a sphere, box, or other shape. The containment vessel 110 further includes a lid 130. The lid 130 is configured to mate with the body 120 to form a hermetic seal. The body 120 and/or the lid 130 can include one or more gaskets, O-rings, or other structures for maintaining a hermetic, pressure resistant seal between the body 120 and the lid 130. In this particular embodiment, the body 120 and the lid 130 are sealed using O-rings 136. The body 120 and the lid 130 form a sealed reaction chamber 140 in which the various methods for making graphene disclosed herein can be carried out. The body 120 and/or the lid 130 can have flanges where bolts can be inserted to clamp the lid 130 and the body 120 together, and also for mating to each other and forming a strong seal with or without the aforementioned gaskets or O-rings.


In this particular embodiment, the body 120 has a flange 122 and the lid 130 has flange 132. In the embodiment shown in FIG. 1, the flanges 130 and 132 form a seal using O-rings, but they can also be configured to thread together or interlock in another fashion to form a seal. In some embodiments, the body 120 and the lid 130 are bolted together using bolts 134. In some embodiments, the body 120 and the lid 130 are clamped together using one or more clamps. The size of the containment vessel 110 is not limited and can be sized up or down according to a desired production scale. In some embodiments, the containment vessel 110 has a radius of at least 4 inches and a length of at least 12 inches. In some embodiments, the containment vessel 110 has a horizontal dimension (e.g., width, length, depth, or radius) of any value in a range corresponding to the following distances, wherein each number can define the upper or lower boundary of the range: 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 25; 30; 40; 50; 60; 70; 80; 90; 100; or greater than 100 inches. In some embodiments, the containment vessel 110 has a vertical dimension (e.g., height) of any value in a range corresponding to the following distances, wherein each number can define the upper or lower boundary of the range: 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 25; 30; 40; 50; 60; 70; 80; 90; 100; or greater than 100 inches.


The bottom of the body 120 can be configured as a collection area. Accordingly, in some embodiments the bottom can be flat, attached permanently, attached with mechanical means, tapered, piston type, or have other configurations. A flat bottom can aid in determining the presence of particles in experimental testing. A tapered bottom can be used for collection purposes in production-scale reactions. As described further herein with reference to FIG. 15, the bottom can also have a collection port for facilitating the removal of graphene products from the reaction chamber.


The apparatus 100 can have one or more ports for providing electrical power to one or more electrodes, sensors, or other equipment located inside the reaction chamber 140. In the embodiment disclosed in FIG. 1, the lid has electrical terminals 150 for transmitting electricity from outside the containment vessel 110 to the inside of the reaction chamber 140. The apparatus 100 has electrodes 142 located inside reaction chamber 140. The electrodes 142, also known as leads, can act as both an anode and cathode, depending on the polarity of the applied voltage. In the embodiment shown in FIG. 1, both electrodes 142 are inserted into separate holes in the lid 130. In some embodiments, the electrodes 142 can be inserted into a common hole. A space between the electrodes is left for a current to jump from anode, where electrons exit the circuit, to cathode, where the electrons re-enter the circuit. In some embodiments, the electrodes are positioned at least 4 inches from the side walls of the body 120 to prevent arcing from the electrodes to the walls or top of the unit. This spacing can be adjusted based on the voltage applied to the electrodes 142 and the properties of the gas inside the reaction chamber 140.


The materials and structure of the electrodes 142 are not limited, and can take any form suitable for creating an electrical arc under the conditions described herein. By way of example, the electrodes can be made of copper, tungsten, other metals, or any other electrically conductive material. The electrodes can be shaped as points, plates (e.g., square, circular, rectangular, or any other planar shape), or any other shape. Each electrode can be made of the same or different material than each other electrode, and each electrode can have the same or different shape than each other electrode. In some embodiments, one or more substrates are positioned between the electrodes. In some embodiments, one or more of the electrodes 142 comprises a clamp for holding a substrate, such as an alligator clip for holding a copper plate substrate. The electrodes can be spaced any distance apart from each other so as to allow an electrical arc to form at a given voltage as described herein. In some embodiments, the anode comprises tungsten and the cathode comprises copper. In some embodiments, the anode comprises a tungsten rod and the cathode comprises a copper plate substrate. Various specific electrode configurations are disclosed herein with reference to the examples described below. The spacing between the electrodes can be any value in a range corresponding to the following distances, wherein each number can define the upper or lower boundary of the range: 0.1; 0.5; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 20; 30; 40; 50; or greater than 50 mm.


In embodiments where substrates are used, substrates can be positioned between electrodes using a rack or other structure for maintaining a desired spacing between electrodes and/or substrates. Alternatively, the substrates can move during use to plate different parts of the substrate. In some embodiments, one or more substrates are embedded inside the inner walls of the containment vessel 110. The spacing between the substrates can be any value in a range corresponding to the following distances, wherein each number can define the upper or lower boundary of the range: 0.1; 0.5; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 20; 30; 40; 50; or greater than 50 mm. The substrates can be made of any conductive material, such as metals including copper. The substrates can have various sizes. In some embodiments, the substrates are about 0.5 mm thick. The thickness of the substrates can be any value in a range corresponding to the following thicknesses, where each number can define the upper or lower boundary of the range: 0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.5; 2; 3; 4; 5; and greater than 5 mm. The substrates can have various shapes including square, circular, or other shapes. The substrates can have an effective surface area of an outer surface (i.e., a surface facing another substrate or electrode between which an electrical arc will form) that is sized according to a desired amount of electrical power to be used. In some embodiments, the effective surface area of a substrate is 2 square inches or less (e.g., a square shaped substrate having a length and width of 1.4 inches). The effective area of the substrates can be any value in a range corresponding to the following areas, where each number can define the upper or lower boundary of the range: 0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1.0; 1.2; 1.3; 1.4; 1.5; 1.6; 1.7; 1.8; 1.9; 2; and greater than 2 square inches. In some embodiments, temperature sensors can be connected to the substrates, such as wirelessly.


The terminals 150 comprise an electrical connection from the electrodes 142 through the lid 130, facilitating an external electrical supply to the electrodes 142. The electrodes generally receive power at a high voltage sufficient to provide an electrical arc at the electrodes 142. This can be adjusted based on the desired spacing between the electrodes 142 and the properties of the gas inside the reaction chamber 140. The electrodes are powered by an electrical supply. The electrical supply can be powered by a battery or an external source, such as a grid power supply (e.g., standard 120 VAC or 240 VAC grid power supply). In some embodiments, the electrical supply comprises a 120 VAC converter (converting 120 volts AC to 12 volts DC) connected to a transformer (e.g., a ZVS flyback driver connected to a transformer) to step up the voltage to, for example, 12,000 V. In some embodiments, the voltage provided to the terminals 150 can be any value in a range corresponding to the following voltages, wherein each number can define the upper or lower boundary of the range: 1; 5; 10; 100; 120; 500; 1,000; 1,500; 2,000; 3,000; 4,000; 5,000; 6,000; 7,000; 8,000; 9,000; 10,000; 11,000; 12,000; 13,000; 14,000; 15,000; 16,000; 17,000; 18,000; 19,000; 20,000; 21,000; 22,000; 23,000; 24,000; 25,000; 26,000; 27,000; 28,000; 29,000; 30,000; 31,000; 32,000; 33,000; 34,000; 35,000; 36,000; 37,000; 38,000; 39,000; 40,000; 41,000; 42,000; 43,000; 44,000; 45,000; 46,000; 47,000; 48,000; 49,000; 50,000; 100,000; 200,000; 230,000; 250,000, and greater than 250,000 volts. In some embodiments, the voltage is a medium voltage of about 1,000 volts. In some embodiments, the voltage is a high voltage of about 230,000 volts. In some embodiments, the current is DC. In some embodiments, the current is AC. In some embodiments, the current provided to the transformer (e.g., flyback transformer) can be any value in a range corresponding to the following currents, wherein each number can define the upper or lower boundary of the range: 0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1; 1.5; 2; 2.5; 3; 3.5; 4; 4.5; 5; 5.5; 6; 6.5; 7; 7.5; 8; 8.5; 9; 9.5; 10; 15; 20; 25; 50; 75; 100; and greater than 100 amps. In some embodiments, the current provided transformer (e.g., flyback transformer) is between 2.5 and 9 amps. In some embodiments, the electrical power provided to the terminals 150 can be any value in a range corresponding to the following power values, wherein each number can define the upper or lower boundary of the range: 2.5; 3; 3.5; 4; 4.5; 5; 5.5; 6; 6.5; 7; 7.5; 8; 8.5; 9; 9.5; 10; 15; 20; 25; 50; 75; 100; and greater than 100 kilowatts.


The apparatus 100 can have one or more ports for transferring fluid into and out of the reaction chamber 140. The apparatus 100 has a fluid port 160. Fluids including gaseous hydrogen and carbon dioxide, or liquids including water, can be transferred into and out of the reaction chamber 140 through the fluid port 160. The fluid port 160 can be in fluid communication with one or more valves, pressure release valves, gas sources, vacuum pumps, storage vessels, or any other fluid source, fluid sink, or fluid flow control device. The apparatus can have one or more ports for allowing one or more sensors to be positioned at least partially within the reaction chamber 140 to measure one or more parameters inside the reaction chamber 140. The apparatus 100 has a first port 162 and a second port 164 provided in the lid 130. The first port 162 allows a temperature sensor 166 to be positioned so that it can measure the temperature inside the reaction chamber 140. The second port 164 allows a pressure sensor 168 to be positioned. In some alternative embodiments, a temperature and/or pressure sensor is mounted in line with the fluid port 160 rather than in the reaction chamber 140 itself.


The temperature sensor 166 is integrated into the chamber to provide real-time monitoring of the internal temperature. Temperature sensors can include thermocouples, resistance temperature detectors (RTDs), thermistors, and any other sensor suitable for measuring the temperatures at which the reaction chamber 140 operates. In some embodiments, the temperature inside the reaction chamber 140 during operation can be any value in a range corresponding to the following temperatures, wherein each number can define the upper or lower boundary of the range: 200; 250; 300; 350; 400; 450; and greater than 450 K. In some embodiments, no heating or cooling elements are used to adjust the temperature inside the reaction chamber 140 during operation. In some embodiments, the temperature inside the reaction chamber 140 during operation is ambient room temperature, or about 65-75 degrees Fahrenheit, and in some embodiments about 70 degrees Fahrenheit. Pressure sensors can include piezoelectric sensors, capacitive pressure sensors, and strain gauge sensors, or any other pressure sensor suitable for measuring the pressures at which the reaction chamber 140 operates. In some embodiments, the pressure inside the reaction chamber 140 during operation can be any value in a range corresponding to the following pressures, wherein each number can define the upper or lower boundary of the range: −15; −14; −13; −12; −11; −10; −9; −8; −7; −6; −5; −4; −3; −2; −1; 0; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 25; 30; 35; 40; 45; 50; 75; 100; 200; 300; 400; 500; 600; 700; 800; 900; 1,000; 1,100; and greater than 1,100 pounds per square inch gauge pressure.


The lid 130 of the containment unit can have any number of holes in it to accommodate any desired number of electrical power or signal wires to pass into the reaction chamber 140, any number of fluid inputs or outputs to be in fluid communication with the reaction chamber 140, and any number of sensors to be positioned to measure inside the reaction chamber 140. In some embodiments, the lid 130 has up to 7 holes in it. In some embodiments, the lid 130 has a minimum of two holes in it. In some embodiments, a hydrogen gas input is positioned in the center of the reaction chamber 140, the electrodes 142 are placed at least one inch away from the hydrogen gas input and two inches or more apart from each other in a direct line, and the other inputs are positioned near the sides of the reaction chamber 140. These spacings are exemplary and not meant to be limiting in any way.


A method of making graphene in accordance with the various embodiments disclosed herein can be carried out using, but not limited to, an apparatus consistent with the apparatus 100 disclosed herein. An apparatus consistent with the apparatus 100 disclosed herein is provided. The reaction chamber is then evacuated to remove air. Once the reaction chamber is evacuated, it is filled with a carbon-containing gas. In some embodiments, the carbon-containing gas is carbon dioxide. In some embodiments, the carbon-containing gas is carbon monoxide. The carbon-containing gas can fill the reaction chamber at a pressure having any value in a range corresponding to the following pressure, wherein each number can define the upper or lower boundary of the range: −15; −14; −13; −12; −11; −10; −9; −8; −7; −6; −5; −4; −3; −2; −1; 0; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 25; 30; 35; 40; 45; 50; 75; 100; 200; 300; 400; 500; 600; 700; 800; 900; 1,000; 1,100; and greater than 1,100 pounds per square inch gauge pressure. In some embodiments, the pressure is 1,070 pounds per square inch gauge pressure or less when the gas is at room temperature. The pressure is generally low enough that the carbon-containing gas remains in a gaseous state at the given operating temperature, so that it is not allowed to convert to a liquid or solid. In some embodiments, the chamber is filled only with the carbon-containing gas and no other gas. In some embodiments, after the reaction chamber is filled with a carbon-containing gas, in some embodiments, hydrogen gas is optionally provided to the reaction chamber in addition to the carbon-containing gas. In the embodiments where hydrogen is optionally added to the reaction chamber, the mixture contains 25% or less hydrogen by volume. In the embodiments where hydrogen is optionally added to the reaction chamber, the mixture contains 1.5% or less hydrogen by mass. In the embodiments where hydrogen is optionally added to the reaction chamber, the mixture of the carbon-containing gas and the hydrogen gas can fill the reaction chamber at a pressure having any value in a range corresponding to the following pressure, wherein each number can define the upper or lower boundary of the range: −15; −14; −13; −12; −11; −10; −9; −8; −7; −6; −5; −4; −3; −2; −1; 0; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 25; 30; 35; 40; 45; 50; 75; 100; 200; 300; 400; 500; 600; 700; 800; 900; 1,000; 1,100; and greater than 1,100 pounds per square inch gauge pressure. In some embodiments, the pressure is 1,070 pounds per square inch gauge pressure or less when the gas is at room temperature. The pressure is generally low enough that the carbon-containing gas remains in a gaseous state at the given operating temperature, so that it is not allowed to convert to a liquid or solid. Finally, electrodes placed inside the reaction chamber are energized with a source of electricity at a voltage sufficient to cause arcing across the electrodes. The voltage provided to the electrodes can be any value in a range corresponding to the following voltages, wherein each number can define the upper or lower boundary of the range: 5; 10; 100; 120; 500; 1,000; 1,500; 2,000; 3,000; 4,000; 5,000; 6,000; 7,000; 8,000; 9,000; 10,000; 11,000; 12,000; 13,000; 14,000; 15,000; 16,000; 17,000; 18,000; 19,000; 20,000; 21,000; 22,000; 23,000; 24,000; 25,000; 26,000; 27,000; 28,000; 29,000; 30,000; 31,000; 32,000; 33,000; 34,000; 35,000; 36,000; 37,000; 38,000; 39,000; 40,000; 41,000; 42,000; 43,000; 44,000; 45,000; 46,000; 47,000; 48,000; 49,000; 50,000; 100,000; 200,000; 230,000; 250,000, and greater than 250,000 volts. In some embodiments, the voltage is a medium voltage of about 1,000 volts. In some embodiments, the voltage is a high voltage of about 230,000 volts. In some embodiments, the current is DC. In some embodiments, the current is AC. The electrodes are energized for a period of time sufficient to form graphene and/or graphene oxide inside the reaction chamber. The electrodes can be energized for a period of time in a range corresponding to the following times, wherein each number can define the upper or lower boundary of the range: 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 16; 17; 18; 19; 20; 21; 22; 23; 24; 25; 26; 27; 28; 29; 30; 31; 32; 33; 34; 35; 36; 37; 38; 39; 40; 41; 42; 43; 44; 45; 46; 47; 48; 49; 50; 51; 52; 53; 54; 55; 56; 57; 58; 59; 60; 70; 80; 90; 100; 120; 180; 240; 300; 360; 500; and greater than 500 seconds. In some embodiments, the polarity of the electrodes is reversed, and the electrical energy is applied at the reversed polarity. The resulting particles comprising graphene and/or graphene oxide can then be removed from the reaction chamber and processed to isolate the graphene.


Referring now to FIG. 15, an alternative embodiment is shown. An apparatus 1800 is generally consistent with the apparatus 100 described above with reference to FIG. 1, except for the addition of an output port 1870 and substrates 1880. That is, the apparatus 1800 has a containment vessel 1810, having a body 1820 and a lid 1830 that form a sealed reaction chamber 1840. The apparatus 1800 further has electrical terminals 1850, electrodes 1842, and a fluid port 1860. In some embodiments, the apparatus 1800 can have one or more additional ports and one or more temperature sensors, pressure sensors, or other sensors. Each of these elements is generally consistent with the corresponding elements of the apparatus 100. The apparatus 1800 further includes an output port 1870, which is a port from which graphene can be collected from the apparatus. The apparatus 1800 also includes a plurality of substrates 1880. A substrate is electrically connected to each electrode 1842, and additional substrates can be spaced between these substrates. The spacing between the substrates can be any value in a range corresponding to the following distances, wherein each number can define the upper or lower boundary of the range: 0.1; 0.5; 1; 2; 3; 4; 5; 6; 7; 8; 9; 10; 11; 12; 13; 14; 15; 20; 30; 40; 50; or greater than 50 mm.


Various methods of removing carbon products produced using the apparatuses and methods disclosed herein can be performed. Sonication, electrolysis, and mechanical removal can all be used. In some embodiments where substrates are used, substrates can be removed from the reaction chamber and carbon can be removed therefrom using sonication, electrolysis, or mechanical removal in a remote location. In some embodiments the apparatus includes an ultrasonic transducer or other device for sonicating the inside of the reaction chamber to remove carbon materials from electrodes, substrates, and sidewalls of the containment vessel.


Hereinafter, the present disclosure will be explained in detail with reference to specific examples. However, the present disclosure is not limited to the embodiments disclosed therein.


Example 1

Phase 1 testing with water displacement.


A carbon material was produced in an apparatus 200 as depicted in schematic form in FIG. 2. The apparatus 200 has a glass containment vessel 210, a reaction chamber 240, and copper electrodes powered by electrical terminals 250, wherein the electrodes include an anode 243 and a cathode 244. The electrodes were positioned 2 inches from each other. The containment vessel 210 was placed in a tub 270, filled with water 245, then inverted. Hydrogen was introduced into the containment vessel 210 through a tube positioned underneath the containment vessel 210. The hydrogen displaced approximately ¼ of the volume of water 245 that was inside the containment vessel 210. Next, dry ice 247 was positioned underneath the containment vessel 210. The dry ice sublimated and produced gaseous carbon dioxide further displaced the water 245 that was inside the containment vessel and filled the remaining ¾ of the volume of the containment vessel 210.


When the water was displaced from the reaction chamber 240 of the containment vessel 210 by the hydrogen and carbon dioxide introduced therein, the electrodes were energized with electricity provided at 18 kV from a flyback transformer provided with an input current of 5 A for a time of about 10 seconds. The pressure inside the reaction chamber 240 was approximately 15 PSI gauge pressure and the temperature was approximately 70 degrees F.


Particles resulting from the reaction were collected from the reaction chamber 240. The particles ranged from about 200-300 μm in width to about 200-500 μm in length. Sample particles were measured at three spots using Raman spectroscopy to determine the presence of carbon materials. FIG. 3 shows the resulting carbon sample that was analyzed. FIG. 4 shows the resulting Raman spectra, which shows peaks around 1360 cm−1 and 1594 cm−1. These peaks are characteristic of carbon materials. The relatively narrow peak at 1594 cm−1 for spot 2 indicates that it may contain a higher crystallinity domain.


Example 2

Phase 2 testing in sealed reaction chamber.


A carbon material was produced in an apparatus 500 as depicted in schematic form in FIG. 5. The apparatus 500 is generally consistent with the apparatus 100 described above with reference to FIG. 1. The apparatus 500 has a containment vessel 510 having a body 520 and a lid 530 defining a reaction chamber 540. The apparatus 500 has two electrodes connected to two electrical terminals 550, wherein the electrodes include an anode 543 and a cathode 544. The apparatus 500 has a gas port 560 in fluid communication with a vacuum source 565 and a gas source 563.


The containment vessel 510 was constructed of steel and had rubber gaskets between the body 520 and the lid 530 to form a hermetic seal. The lid 530 was secured to the body 520 using bolts. The lid had holes drilled into it to allow for the gas port 560 and electrical terminals 550 to pass through the lid into the reaction chamber 540. The gas port 560 included a tapped hole with a valve connector threaded into it. In the tapped holes where the electrical terminals are allowed to pass through the lid to the electrodes, a hollow screw was inserted into each tapped hole. A wire wrapped with plumber's tape was passed through each hole and then each hole was filled with silicone to form a hermetic seal. All threads were wrapped with plumber's tape to ensure a seal. A pressure sensor was mounted in fluid communication with the gas input 560. A pressure release valve was also mounted in fluid communication with the gas input 560. The pressure release valve is closed during operation and can be opened to release pressure from the unit after use. When closed the valve allows the pressure sensor to be active and for the unit to be pressurized. The pressure release valve can also be opened if an overpressure situation is detected.


The electrodes were made of copper and configured as point source electrodes (i.e., two tips facing each other from which the electrical arc is generated). The electrodes were positioned 1 inch from each other.


The rection chamber 540 was evacuated using the vacuum source 565 (i.e., a vacuum pump). Next, gaseous carbon dioxide was introduced into the reaction chamber 540 via the gas input 563 and filled to a pressure of 20 PSI. The carbon dioxide was provided from a cylinder containing compressed carbon dioxide. Then, gaseous hydrogen was introduced into the reaction chamber 540 via the gas input 563. The hydrogen was provided from a cylinder containing pressurized hydrogen. The reaction chamber was filled to a gauge pressure of 30 PSI, including both the carbon dioxide and hydrogen.


Once the reaction chamber was filled with carbon dioxide and hydrogen to a gauge pressure of 30 PSI and at an ambient temperature of about 70 degrees F., the electrodes were energized with electricity provided at 30 kV from a flyback transformer provided with an input current of 6 A for a time of about 60 seconds, thereby forming an electrical arc between the electrodes.


Particles resulting from the reaction were collected from the reaction chamber 540. Sample particles were measured at numerous spots using Raman spectroscopy to determine the presence of carbon materials. FIG. 6 shows the resulting carbon sample. FIG. 7 shows the resulting Raman spectra at five exemplary spots, which shows peaks around 1360 cm−1 and 1594 cm−1. These peaks are characteristic of carbon materials. The peak at 1360, known as the D-band, indicates defects, edges, or disorder within a carbon material. The peak at 1594, known as the G-band, indicates the amount of carbon atoms that create aromatic rings. Aromatic rings are the well-known hexagonal lattice of graphene. A higher the ratio of the D-band compared to the G-band (known as the D/G ratio) indicates a higher quality of the material.


Example 3

Phase 3A testing with single substrate in sealed reaction chamber.


A carbon material was produced in the same apparatus in which Example 2, Phase 2 testing was conducted. That is, it was conducted in an apparatus 500 as described above with reference to FIG. 5. The setup was modified so that the cathode 544 was electrically connected to a substrate. The substrate was a 24 gauge copper plate having dimension of 2 cm×2 cm. It was placed 2 cm from the anode.


As a first step, the rection chamber 540 was evacuated using the vacuum source 565 (i.e., a vacuum pump). Next, gaseous carbon dioxide was introduced into the reaction chamber 540 via the gas input 563 and filled to a gauge pressure of 10 PSI. The carbon dioxide was provided from a cylinder containing compressed carbon dioxide.


Once the reaction chamber was filled with carbon dioxide at 10 PSI and at an ambient temperature of about 70 degrees F., the electrodes were energized with electricity provided at 12 kV from a flyback transformer provided with an input current of 4 A for a time of about 5 seconds, thereby forming an electrical arc between the anode 543 and the substrate connected to the cathode 544.


The substrate was covered with a gray and black material following the reaction. FIG. 8 shows and image of the substrate with the resultant material thereon. The substrate was analyzed using Raman spectroscopy to determine the presence of carbon materials in the resultant material. FIG. 9 shows the resulting Raman spectrum for the material on the substrate, which shows a peak of around 1587 cm−1. This peak indicates the presence of aromatic carbon rings. The width of the peak indicates that the aromatic carbon rings are generally left open or deformed. The Raman spectrum does not indicate D-band or 2D band peaks, which indicates the sample is highly susceptible to change.


Example 4

Phase 3B testing with multiple substrates in sealed reaction chamber.


A carbon material was produced in the same apparatus in which Example 2, Phase 2 testing was conducted. That is, it was conducted in an apparatus 500 as described above with reference to FIG. 5. The setup was modified so that the cathode 544 was connected to a substrate 580, and a plurality of substrates 580 were positioned between the substrate connected to the cathode 544 and the anode 543. This electrode configuration is shown in schematic form in FIG. 10. The anode 543 was made of tungsten and the cathode 544 was made of copper. Each substrate was a 24-gauge copper plate having dimensions of 2 cm×2 cm. The substrates were positioned at different spacings from each other, ranging from a spacing of 5 mm to a of 1.5 cm from each other.


The rection chamber 540 was evacuated using the vacuum source 565 (i.e., a vacuum pump). Next, gaseous carbon dioxide was introduced into the reaction chamber 540 via the gas input 563 and filled to a gauge pressure of 15 PSI. The carbon dioxide was provided from a cylinder containing compressed carbon dioxide.


Once the reaction chamber was filled with carbon dioxide at 15 PSI and at an ambient temperature of about 70 degrees F., the electrodes were energized with electricity provided at 12 kV from a flyback transformer provided with an input current of 4 A for a time of 60 seconds, thereby forming an electrical arc between the substrate connected to an electrode, each other substrate, and the other electrode.


The substrates were covered with a gray and black material following the reaction. The substrates were subjected to sonication in isopropyl alcohol to remove the material. FIG. 11 shows and image of the resultant material. The resultant material was analyzed using Raman spectroscopy to determine the presence of carbon materials. FIG. 12 shows the resulting Raman spectrum for the material on the substrate, which shows peaks around 1263 cm−1, 1433 cm−1, 1455 cm−1, and 1618 cm−1. The band at 1618 cm−1 is indicative of the graphene oxide G band, and the other three bands indicate the presence of aromatic carbon rings with oxygen substitutes.


Example 5

Phase 3C testing with substrate in atmospheric reaction chamber.


A carbon material was produced in the same apparatus in which Example 2, Phase 2 testing was conducted. That is, it was conducted in an apparatus 500 as described above with reference to FIG. 5. The setup was modified so that the cathode 544 was connected to a substrate. The anode 543 was made of tungsten and the cathode 544 was made of copper. The substrate was a 0.5 mm copper plate having dimensions of 2 cm×2 cm. The substrate was spaced 2 cm from the anode.


The rection chamber 540 was evacuated using the vacuum source 565 (i.e., a vacuum pump). Next, gaseous carbon dioxide was introduced into the reaction chamber 540 via the gas input 563 and filled to a gauge pressure of 0 PSI, i.e., atmospheric pressure. The carbon dioxide was provided from a cylinder containing compressed carbon dioxide. The lid of the vessel was loosened so that the internal pressure would remain at the ambient atmospheric pressure.


Once the reaction chamber was filled with carbon dioxide at atmospheric pressure and at an ambient temperature of about 70 degrees F., the electrodes were energized with electricity provided at 12 kV from a flyback transformer provided with an input current of 5 A for a time of 60 seconds, thereby forming an electrical arc between the substrate connected the cathode 544 and the anode 543. Next, the polarity of the electrodes was reversed so that the anode 543 would act as a cathode, and the cathode 544 would act as an anode. Nothing else was changed. The electrodes were energized at this reversed polarity at 12 kV from a flyback transformer provided with an input current of 5 A for a time of 60 seconds, thereby forming an electrical arc between the substrate connected to the cathode 544 (now acting as an anode) and the anode 543 (now acting as a cathode).


The substrate was covered with a gray and black material following the reaction. The substrate was subjected to sonication to remove the material. FIG. 13 shows an image of the resultant material. A sample of the resultant material was analyzed using Raman spectroscopy to determine the presence of carbon materials. FIG. 14 shows the resulting Raman spectrum for the resultant material, which shows peaks around 1578 cm−1, 2436 cm−1, and 2606 cm−1. The peak at 1578 cm−1 is indicative of the graphene G band. The peak at 2436 cm−1 is indicative of nitrogen, which might have been introduced from ambient air in this unsealed test. The peak at 2606 cm−1 is indicative of the graphene 2D band, which might be weak due to the many layers of material. These results confirm the reduced graphene oxide process and process as a whole.


RESULTS

The results of the experiments indicate graphene D-band ranges occurring at 1260-1455, G-band ranges occurring at 1555-1657, and 2D band ranges occurring at 2500-2800 on a Raman spectrum. These results indicate the creation of amorphous carbon, graphene oxide, reduced graphene oxide, and other carbon allotropes as a result of the apparatuses and methods disclosed herein. The produced aromatic carbon is highly open to functionalization.


The examples have been provided for illustration of the present disclosure, but the disclosure is not limited thereto. It is clear to those skilled in the art that the examples can be changed and modified in various ways within the scope of the present disclosure.

Claims
  • 1. A method for making carbon materials comprising: evacuating a reaction chamber;filling the evacuated reaction chamber with a carbon-containing gas; andenergizing a first electrode inside the reaction chamber to create an arc between the first electrode and a second electrode in the presence of the carbon-containing gas.
  • 2. The method of claim 1, wherein the reaction chamber is filled with a carbon-containing gas to a gauge pressure of 0 PSI or greater.
  • 3. The method of claim 1, wherein the reaction chamber is filled with a carbon-containing gas at a temperature of about 70 degrees Fahrenheit.
  • 4. The method of claim 1, wherein energizing the first electrode comprises applying greater than 10,000 volts DC across the first electrode and second electrode.
  • 5. The method of claim 1, wherein the first electrode is energized for 5 seconds or greater.
  • 6. The method of claim 1, wherein the first electrode is an anode comprising tungsten and the second electrode is a cathode comprising copper.
  • 7. The method of claim 1, wherein one or more copper substrates are electrically connected to the second electrode.
  • 8. The method of claim 7, further comprising removing carbon material from the one or more copper substrates after the first electrode and second electrode are energized.
  • 9. The method of claim 1, wherein the carbon-containing gas comprises carbon dioxide.
  • 10. An apparatus for making carbon materials comprising: a body defining a reaction chamber;a lid configured to mate with the body to form a hermetic seal, the lid comprising a port for the passage of fluid and a plurality of electrical terminals;an anode and a cathode positioned inside the reaction chamber, the anode and cathode electrically connected to the plurality of electrical terminals; anda power source electrically connected to the electrical terminals.
  • 11. The apparatus of claim 10, wherein the lid comprises a flange configured to mate with a flange on the body.
  • 12. The apparatus of claim 11, wherein each flange comprises through holes for receiving bolts to clamp the flanges together.
  • 13. The apparatus of claim 10, wherein the power source is configured to provide DC current at 10,000 volts or greater.
  • 14. The apparatus of claim 13, wherein the power source comprises a flyback transformer.
  • 15. The apparatus of claim 10, wherein the anode comprises tungsten.
  • 16. The apparatus of claim 10, wherein the cathode comprises copper.
  • 17. The apparatus of claim 10, further comprising one or more copper substrates electrically connected to the cathode.
  • 18. The apparatus of claim 10, wherein the anode and the cathode are spaced less than or equal to two inches from each other.
  • 19. An apparatus for making carbon materials comprising: a cylindrical body defining a reaction chamber, the body having a first flange around an upper opening of the body;a lid having a second flange configured to mate with the first flange to form a hermetic seal, the lid comprising first hole for the passage of fluid and second hole for the passage of wires;a manifold connected to the first hole, the manifold in fluid communication with first source comprising compressed carbon dioxide and a second source comprising a vacuum pump;an anode and a cathode positioned inside the reaction chamber, the anode and cathode electrically connected to wires passing through the second hole;an electrical power supply for providing electricity to the anode and cathode via the wires, the electrical power supply configured to provide at least 10,000 volts DC;wherein the chamber has a radius of at least 4 inches and a length of at least 12 inches;wherein the anode and cathode are each positioned at least 4 inches from a sidewall of the body; and wherein the anode and cathode are positioned at least 1 mm from each other.
  • 20. The apparatus of claim 19, further comprising one or more copper substrates electrically connected to the cathode.
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/606,239, filed Dec. 5, 2023, the contents of which is incorporated by reference herein in its entirety.

Provisional Applications (1)
Number Date Country
63606239 Dec 2023 US