Submerged-Plasma Process for the High Rate Production of Graphene Nanoflakes

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Invention Summary:

Carbon nanomaterials, such as nanotubes and graphene, have received a lot of attention because of their excellent and one-of-a-kind electrical, physical, and morphological properties. One of graphene's most notable properties is its high carrier mobility at room temperature. As a result, nanographene is appealing as a channel material for the next generation of ultrafast electronics or nanofiller for thermal management in multifunctional composites. Generally, these materials are often synthesized using expensive and time-consuming processes like chemical vapor deposition (CVD) or arc discharge methods which have low throughput.

Rutgers researchers have developed a novel synthesis process of submerged plasma for high-rate production of graphene nanoparticles. The current invention relates to a method by which methane is fed into an inductively-coupled plasma or a high-enthalpy arc plasma, where rapid precursor decomposition-vaporization (pyrolysis) occurs. The plume of the plasma containing pyrolyzed precursor is directed into and submerged in a bath of chilled, high purity water or other liquid, where condensation-quenching of vaporized species takes place, leading to the formation of graphene nanoflakes. Researchers have reported high-rate production of GNFs capable of pounds/hour.

Advantages:

• The process is tunable, scalable, of higher quenching efficiency, and higher collection efficiency (by filtration).
• The yield of the Rutgers method is much higher (<grams/hour vs. pounds/hour).

Market Applications:

• Energy and thermal application
• Optoelectronics applications
• Structural applications

Intellectual Property & Development Status: Patent pending. Available for licensing and/or research collaboration.