Patent
US 10,059,591METHOD OF PRODUCING GRAPHENE FROM A HYDROCARBON GAS AND LIQUID METAL CATALYSTS
William Brenden CARLSON
US
Copyright © 2026 Matter42. All rights reserved.
Patent
Atlas literature
Patent
US 10,059,591Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1 depicts a cutaway side view of an illustrative reaction chamber according to an embodiment. [0010]
FIG. 2 depicts a flow diagram of an illustrative method of producing graphene according to a first embodiment. [0011]
FIG. 3 depicts a flow diagram of an illustrative method of producing graphene according to a second embodiment.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of producing graphene, the method comprising: adding at least one liquid metal catalyst in a reaction chamber; adding at least one hydrocarbon gas in the reaction chamber; allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product;[[and]] dehydrogenating the product to produce [[the]]graphene; and removing the at least one liquid metal catalyst from the reaction chamber by straining the at least one liquid metal catalyst through a porous substrate, wherein the graphene dispersed in the liquid metal catalyst is captured by the porous substrate. Currently amended
The method of claim 1, further comprising combining the at least one liquid metal catalyst with at least one additive prior to contacting with the at least one hydrocarbon gas. Previously presented
The method of claim 1, further comprising placing a reducing agent in the reaction chamber after adding the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, further comprising dissolving the hydrocarbon gas in a solvent prior to placing the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another at a temperature of about [[300 0 C]]300 0 C to about [[400 0 C]]400 0 C. Currently amended
The method of claim 1, wherein adding[[the]] the hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 1, wherein the at least one liquid metal catalyst is a molten metal catalyst. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding at least one liquid metal catalyst comprising mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an amalgam comprising mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, and wolfram. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy having a melting point equal to or less than about [[150 ° C]]150 0 C. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one liquid metal catalyst and the at least one hydrocarbon gas, [[where]]wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Previously presented
The method of claim 1, wherein dehydrogenating the product comprises producing the graphene containing substantially no defects. Previously presented
Canceled
-7. Canceled
Canceled
-1 3. Canceled
Canceled
Canceled
Canceled
-37. Canceled
Canceled
A method of producing graphene, the method comprising: combining at least one metal catalyst with an additive; adding the at least one metal catalyst and the additive into a reaction chamber; evacuating any gas in the reaction chamber; adding at least one hydrocarbon gas into the reaction chamber; adding a solvent into the reaction chamber; heating the reaction chamber; allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product; dehydrogenating the product to produce the graphene; removing the at least one metal catalyst from the reaction chamber; removing the solvent from the reaction chamber; and collecting the graphene on a porous substrate in the reaction chamber. Original
The method of claim 38, further comprising melting the at least one metal catalyst prior to adding the at least one hydrocarbon gas into the reaction chamber. Original
The method of claim 38, wherein combining comprises combining with sodium carbonate, potassium nitrate, lithium carbonate, potassium carbonate, rubidium carbonate, cesium carbonate, magnesium carbonate, lithium nitrate, sodium nitrate, rubidium nitrate, cesium nitrate, magnesium nitrate, calcium nitrate, strontium nitrate, barium nitrate, zin c nitrate, lead nitrate, copper nitrate, iron nitrate, chromium nitrate, cobalt nitrate, nickel nitrate, titanium nitrate, lithium nitrite, sodium nitrite, rubidium nitrite, cesium nitrite, magnesium nitrite, calcium nitrite, strontium nitrite, barium nitrite, zin c nitrite, lead nitrite, copper nitrite, iron nitrite, chromium nitrite, cobalt nitrite, nickel nitrite, titanium nitrite, lithium chlorite, sodium chlorite, rubidium chlorite, cesium chlorite, magnesium chlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite and magnesium hypochlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite, magnesium hypochlorite, calcium hypochlorite, strontium hypochlorite, barium hypochlorite, zin c hypochlorite, or a combination thereof. Previously presented
The method of claim 38, wherein removing the at least one metal catalyst comprises straining the at least one metal catalyst through the porous substrate, wherein the graphene that is dispersed in the metal catalyst is captured by the porous substrate. Original
The method of claim 38, wherein adding a solvent comprises adding ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, glycerol, sorbitol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, galactitol, fucitol, iditol, inositol, dimethyl carbonate, diethyl carbonate, propylene carbonate, ethylene carbonate, or a combination thereof. Previously presented
The method of claim 38, wherein heating the reaction chamber comprises heating to a temperature of about [[300 ° C]]300 0 C to about [[400 ° C]]400 0 C. Currently amended
The method of claim 38, wherein adding the at least one hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining a molten metal catalyst. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining at least one metal catalyst including mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an amalgam including mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, wolfram. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy having a melting point equal to or less than about [[150 ° C]]150 °C. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one metal catalyst and the at least one hydrocarbon gas, wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Currently amended
4 1-42. Canceled
The method of claim 41, further comprising placing a reducing agent in the reaction chamber after injecting the at least one hydrocarbon gas in the reaction chamber, wherein the reducing agent comprises one or more of methane, ethane, propane, butane, pentane, hexane, hydrogen, lithium, sodium, potassium, rubidium, cesium, and magnesium. Previously presented
Canceled
Canceled
46-47. Canceled
Canceled
Canceled
Canceled
60-61. Canceled
Canceled
Materials described outside the worked examples.
liquid metal catalyst
hydrocarbon gas
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | 300–400 °C | — |
Duration | 300–18000 s |
Patent
Atlas literature
Patent
US 10,059,591Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1 depicts a cutaway side view of an illustrative reaction chamber according to an embodiment. [0010]
FIG. 2 depicts a flow diagram of an illustrative method of producing graphene according to a first embodiment. [0011]
FIG. 3 depicts a flow diagram of an illustrative method of producing graphene according to a second embodiment.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of producing graphene, the method comprising: adding at least one liquid metal catalyst in a reaction chamber; adding at least one hydrocarbon gas in the reaction chamber; allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product;[[and]] dehydrogenating the product to produce [[the]]graphene; and removing the at least one liquid metal catalyst from the reaction chamber by straining the at least one liquid metal catalyst through a porous substrate, wherein the graphene dispersed in the liquid metal catalyst is captured by the porous substrate. Currently amended
The method of claim 1, further comprising combining the at least one liquid metal catalyst with at least one additive prior to contacting with the at least one hydrocarbon gas. Previously presented
The method of claim 1, further comprising placing a reducing agent in the reaction chamber after adding the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, further comprising dissolving the hydrocarbon gas in a solvent prior to placing the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another at a temperature of about [[300 0 C]]300 0 C to about [[400 0 C]]400 0 C. Currently amended
The method of claim 1, wherein adding[[the]] the hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 1, wherein the at least one liquid metal catalyst is a molten metal catalyst. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding at least one liquid metal catalyst comprising mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an amalgam comprising mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, and wolfram. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy having a melting point equal to or less than about [[150 ° C]]150 0 C. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one liquid metal catalyst and the at least one hydrocarbon gas, [[where]]wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Previously presented
The method of claim 1, wherein dehydrogenating the product comprises producing the graphene containing substantially no defects. Previously presented
Canceled
-7. Canceled
Canceled
-1 3. Canceled
Canceled
Canceled
Canceled
-37. Canceled
Canceled
A method of producing graphene, the method comprising: combining at least one metal catalyst with an additive; adding the at least one metal catalyst and the additive into a reaction chamber; evacuating any gas in the reaction chamber; adding at least one hydrocarbon gas into the reaction chamber; adding a solvent into the reaction chamber; heating the reaction chamber; allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product; dehydrogenating the product to produce the graphene; removing the at least one metal catalyst from the reaction chamber; removing the solvent from the reaction chamber; and collecting the graphene on a porous substrate in the reaction chamber. Original
The method of claim 38, further comprising melting the at least one metal catalyst prior to adding the at least one hydrocarbon gas into the reaction chamber. Original
The method of claim 38, wherein combining comprises combining with sodium carbonate, potassium nitrate, lithium carbonate, potassium carbonate, rubidium carbonate, cesium carbonate, magnesium carbonate, lithium nitrate, sodium nitrate, rubidium nitrate, cesium nitrate, magnesium nitrate, calcium nitrate, strontium nitrate, barium nitrate, zin c nitrate, lead nitrate, copper nitrate, iron nitrate, chromium nitrate, cobalt nitrate, nickel nitrate, titanium nitrate, lithium nitrite, sodium nitrite, rubidium nitrite, cesium nitrite, magnesium nitrite, calcium nitrite, strontium nitrite, barium nitrite, zin c nitrite, lead nitrite, copper nitrite, iron nitrite, chromium nitrite, cobalt nitrite, nickel nitrite, titanium nitrite, lithium chlorite, sodium chlorite, rubidium chlorite, cesium chlorite, magnesium chlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite and magnesium hypochlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite, magnesium hypochlorite, calcium hypochlorite, strontium hypochlorite, barium hypochlorite, zin c hypochlorite, or a combination thereof. Previously presented
The method of claim 38, wherein removing the at least one metal catalyst comprises straining the at least one metal catalyst through the porous substrate, wherein the graphene that is dispersed in the metal catalyst is captured by the porous substrate. Original
The method of claim 38, wherein adding a solvent comprises adding ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, glycerol, sorbitol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, galactitol, fucitol, iditol, inositol, dimethyl carbonate, diethyl carbonate, propylene carbonate, ethylene carbonate, or a combination thereof. Previously presented
The method of claim 38, wherein heating the reaction chamber comprises heating to a temperature of about [[300 ° C]]300 0 C to about [[400 ° C]]400 0 C. Currently amended
The method of claim 38, wherein adding the at least one hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining a molten metal catalyst. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining at least one metal catalyst including mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an amalgam including mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, wolfram. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy having a melting point equal to or less than about [[150 ° C]]150 °C. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one metal catalyst and the at least one hydrocarbon gas, wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Currently amended
4 1-42. Canceled
The method of claim 41, further comprising placing a reducing agent in the reaction chamber after injecting the at least one hydrocarbon gas in the reaction chamber, wherein the reducing agent comprises one or more of methane, ethane, propane, butane, pentane, hexane, hydrogen, lithium, sodium, potassium, rubidium, cesium, and magnesium. Previously presented
Canceled
Canceled
46-47. Canceled
Canceled
Canceled
Canceled
60-61. Canceled
Canceled
Materials described outside the worked examples.
liquid metal catalyst
hydrocarbon gas
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | 300–400 °C | — |
Duration | 300–18000 s |
Patent
Atlas literature
Patent
US 10,059,591Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1 depicts a cutaway side view of an illustrative reaction chamber according to an embodiment. [0010]
FIG. 2 depicts a flow diagram of an illustrative method of producing graphene according to a first embodiment. [0011]
FIG. 3 depicts a flow diagram of an illustrative method of producing graphene according to a second embodiment.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of producing graphene, the method comprising: adding at least one liquid metal catalyst in a reaction chamber; adding at least one hydrocarbon gas in the reaction chamber; allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product;[[and]] dehydrogenating the product to produce [[the]]graphene; and removing the at least one liquid metal catalyst from the reaction chamber by straining the at least one liquid metal catalyst through a porous substrate, wherein the graphene dispersed in the liquid metal catalyst is captured by the porous substrate. Currently amended
The method of claim 1, further comprising combining the at least one liquid metal catalyst with at least one additive prior to contacting with the at least one hydrocarbon gas. Previously presented
The method of claim 1, further comprising placing a reducing agent in the reaction chamber after adding the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, further comprising dissolving the hydrocarbon gas in a solvent prior to placing the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another at a temperature of about [[300 0 C]]300 0 C to about [[400 0 C]]400 0 C. Currently amended
The method of claim 1, wherein adding[[the]] the hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 1, wherein the at least one liquid metal catalyst is a molten metal catalyst. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding at least one liquid metal catalyst comprising mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an amalgam comprising mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, and wolfram. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy having a melting point equal to or less than about [[150 ° C]]150 0 C. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one liquid metal catalyst and the at least one hydrocarbon gas, [[where]]wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Previously presented
The method of claim 1, wherein dehydrogenating the product comprises producing the graphene containing substantially no defects. Previously presented
Canceled
-7. Canceled
Canceled
-1 3. Canceled
Canceled
Canceled
Canceled
-37. Canceled
Canceled
A method of producing graphene, the method comprising: combining at least one metal catalyst with an additive; adding the at least one metal catalyst and the additive into a reaction chamber; evacuating any gas in the reaction chamber; adding at least one hydrocarbon gas into the reaction chamber; adding a solvent into the reaction chamber; heating the reaction chamber; allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product; dehydrogenating the product to produce the graphene; removing the at least one metal catalyst from the reaction chamber; removing the solvent from the reaction chamber; and collecting the graphene on a porous substrate in the reaction chamber. Original
The method of claim 38, further comprising melting the at least one metal catalyst prior to adding the at least one hydrocarbon gas into the reaction chamber. Original
The method of claim 38, wherein combining comprises combining with sodium carbonate, potassium nitrate, lithium carbonate, potassium carbonate, rubidium carbonate, cesium carbonate, magnesium carbonate, lithium nitrate, sodium nitrate, rubidium nitrate, cesium nitrate, magnesium nitrate, calcium nitrate, strontium nitrate, barium nitrate, zin c nitrate, lead nitrate, copper nitrate, iron nitrate, chromium nitrate, cobalt nitrate, nickel nitrate, titanium nitrate, lithium nitrite, sodium nitrite, rubidium nitrite, cesium nitrite, magnesium nitrite, calcium nitrite, strontium nitrite, barium nitrite, zin c nitrite, lead nitrite, copper nitrite, iron nitrite, chromium nitrite, cobalt nitrite, nickel nitrite, titanium nitrite, lithium chlorite, sodium chlorite, rubidium chlorite, cesium chlorite, magnesium chlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite and magnesium hypochlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite, magnesium hypochlorite, calcium hypochlorite, strontium hypochlorite, barium hypochlorite, zin c hypochlorite, or a combination thereof. Previously presented
The method of claim 38, wherein removing the at least one metal catalyst comprises straining the at least one metal catalyst through the porous substrate, wherein the graphene that is dispersed in the metal catalyst is captured by the porous substrate. Original
The method of claim 38, wherein adding a solvent comprises adding ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, glycerol, sorbitol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, galactitol, fucitol, iditol, inositol, dimethyl carbonate, diethyl carbonate, propylene carbonate, ethylene carbonate, or a combination thereof. Previously presented
The method of claim 38, wherein heating the reaction chamber comprises heating to a temperature of about [[300 ° C]]300 0 C to about [[400 ° C]]400 0 C. Currently amended
The method of claim 38, wherein adding the at least one hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining a molten metal catalyst. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining at least one metal catalyst including mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an amalgam including mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, wolfram. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy having a melting point equal to or less than about [[150 ° C]]150 °C. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one metal catalyst and the at least one hydrocarbon gas, wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Currently amended
4 1-42. Canceled
The method of claim 41, further comprising placing a reducing agent in the reaction chamber after injecting the at least one hydrocarbon gas in the reaction chamber, wherein the reducing agent comprises one or more of methane, ethane, propane, butane, pentane, hexane, hydrogen, lithium, sodium, potassium, rubidium, cesium, and magnesium. Previously presented
Canceled
Canceled
46-47. Canceled
Canceled
Canceled
Canceled
60-61. Canceled
Canceled
Materials described outside the worked examples.
liquid metal catalyst
hydrocarbon gas
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | 300–400 °C | — |
Duration | 300–18000 s |
Patent
Atlas literature
Patent
US 10,059,591Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1 depicts a cutaway side view of an illustrative reaction chamber according to an embodiment. [0010]
FIG. 2 depicts a flow diagram of an illustrative method of producing graphene according to a first embodiment. [0011]
FIG. 3 depicts a flow diagram of an illustrative method of producing graphene according to a second embodiment.
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A method of producing graphene, the method comprising: adding at least one liquid metal catalyst in a reaction chamber; adding at least one hydrocarbon gas in the reaction chamber; allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product;[[and]] dehydrogenating the product to produce [[the]]graphene; and removing the at least one liquid metal catalyst from the reaction chamber by straining the at least one liquid metal catalyst through a porous substrate, wherein the graphene dispersed in the liquid metal catalyst is captured by the porous substrate. Currently amended
The method of claim 1, further comprising combining the at least one liquid metal catalyst with at least one additive prior to contacting with the at least one hydrocarbon gas. Previously presented
The method of claim 1, further comprising placing a reducing agent in the reaction chamber after adding the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, further comprising dissolving the hydrocarbon gas in a solvent prior to placing the at least one hydrocarbon gas in the reaction chamber. Original
The method of claim 1, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another at a temperature of about [[300 0 C]]300 0 C to about [[400 0 C]]400 0 C. Currently amended
The method of claim 1, wherein adding[[the]] the hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 1, wherein the at least one liquid metal catalyst is a molten metal catalyst. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding at least one liquid metal catalyst comprising mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an amalgam comprising mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, and wolfram. Previously presented
The method of claim 1, wherein adding the at least one liquid metal catalyst comprises adding an alloy having a melting point equal to or less than about [[150 ° C]]150 0 C. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one liquid metal catalyst and the at least one hydrocarbon gas, [[where]]wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 1, wherein allowing the at least one liquid metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Previously presented
The method of claim 1, wherein dehydrogenating the product comprises producing the graphene containing substantially no defects. Previously presented
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A method of producing graphene, the method comprising: combining at least one metal catalyst with an additive; adding the at least one metal catalyst and the additive into a reaction chamber; evacuating any gas in the reaction chamber; adding at least one hydrocarbon gas into the reaction chamber; adding a solvent into the reaction chamber; heating the reaction chamber; allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another to produce a product; dehydrogenating the product to produce the graphene; removing the at least one metal catalyst from the reaction chamber; removing the solvent from the reaction chamber; and collecting the graphene on a porous substrate in the reaction chamber. Original
The method of claim 38, further comprising melting the at least one metal catalyst prior to adding the at least one hydrocarbon gas into the reaction chamber. Original
The method of claim 38, wherein combining comprises combining with sodium carbonate, potassium nitrate, lithium carbonate, potassium carbonate, rubidium carbonate, cesium carbonate, magnesium carbonate, lithium nitrate, sodium nitrate, rubidium nitrate, cesium nitrate, magnesium nitrate, calcium nitrate, strontium nitrate, barium nitrate, zin c nitrate, lead nitrate, copper nitrate, iron nitrate, chromium nitrate, cobalt nitrate, nickel nitrate, titanium nitrate, lithium nitrite, sodium nitrite, rubidium nitrite, cesium nitrite, magnesium nitrite, calcium nitrite, strontium nitrite, barium nitrite, zin c nitrite, lead nitrite, copper nitrite, iron nitrite, chromium nitrite, cobalt nitrite, nickel nitrite, titanium nitrite, lithium chlorite, sodium chlorite, rubidium chlorite, cesium chlorite, magnesium chlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite and magnesium hypochlorite, calcium chlorite, strontium chlorite, barium chlorite, zin c chlorite, lead chlorite, copper chlorite, iron chlorite, chromium chlorite, cobalt chlorite, nickel chlorite, titanium chlorite, lithium hypochlorite, sodium hypochlorite, rubidium hypochlorite, cesium hypochlorite, magnesium hypochlorite, calcium hypochlorite, strontium hypochlorite, barium hypochlorite, zin c hypochlorite, or a combination thereof. Previously presented
The method of claim 38, wherein removing the at least one metal catalyst comprises straining the at least one metal catalyst through the porous substrate, wherein the graphene that is dispersed in the metal catalyst is captured by the porous substrate. Original
The method of claim 38, wherein adding a solvent comprises adding ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, glycerol, sorbitol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, galactitol, fucitol, iditol, inositol, dimethyl carbonate, diethyl carbonate, propylene carbonate, ethylene carbonate, or a combination thereof. Previously presented
The method of claim 38, wherein heating the reaction chamber comprises heating to a temperature of about [[300 ° C]]300 0 C to about [[400 ° C]]400 0 C. Currently amended
The method of claim 38, wherein adding the at least one hydrocarbon gas comprises adding methane, ethane, ethyne, ethene, carbon monoxide, ethanol, propane, butane, butadiene, pentane, pentene, cyclopentadiene, hexane, cyclohexane, benzene, toluene, carbon dioxide, chloromethane, dichloromethane, chloroform, bromomethane, dibromomethane, bromoform, iodomethane, diodomethane, iodoform, carbon tetrachloride, carbon tetrabromide, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining a molten metal catalyst. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining at least one metal catalyst including mercury, bismuth, cesium, gallium, nickel, silver, an alloy thereof, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy including a Wood's metal, a Rose's metal, a Field's metal, cerrosafe, cerrolow, or a combination thereof. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an amalgam including mercury and at least one of bismuth, potassium, lithium, sodium, rubidium, cesium, magnesium, calcium, strontium, barium, copper, silver, gold, platinum, nickel, palladium, cobalt, rhodium, iridium, iron, ruthenium, rhenium, wolfram. Currently amended
The method of claim 38, wherein combining the at least one metal catalyst comprises combining an alloy having a melting point equal to or less than about [[150 ° C]]150 °C. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises contacting at an interface between the at least one metal catalyst and the at least one hydrocarbon gas, wherein the interface is a substantially horizontal surface with respect to a bottom surface of the reaction chamber. Currently amended
The method of claim 38, wherein allowing the at least one metal catalyst and the at least one hydrocarbon gas to contact one another comprises producing the product by a (2+2+2) cycloaddition reaction. Currently amended
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The method of claim 41, further comprising placing a reducing agent in the reaction chamber after injecting the at least one hydrocarbon gas in the reaction chamber, wherein the reducing agent comprises one or more of methane, ethane, propane, butane, pentane, hexane, hydrogen, lithium, sodium, potassium, rubidium, cesium, and magnesium. Previously presented
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Materials described outside the worked examples.
liquid metal catalyst
hydrocarbon gas
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
Temperature | 300–400 °C | — |
Duration | 300–18000 s |
additive (salts including carbonates, nitrates, nitrites, chlorites, hypochlorites)
reducing agent
solvent (glycols and carbonates)
low-melting metal alloy (Wood's metal, Rose's metal, Field's metal, cerrosafe, cerrolow)
mercury amalgam
| — |
additive (salts including carbonates, nitrates, nitrites, chlorites, hypochlorites)
reducing agent
solvent (glycols and carbonates)
low-melting metal alloy (Wood's metal, Rose's metal, Field's metal, cerrosafe, cerrolow)
mercury amalgam
| — |
additive (salts including carbonates, nitrates, nitrites, chlorites, hypochlorites)
reducing agent
solvent (glycols and carbonates)
low-melting metal alloy (Wood's metal, Rose's metal, Field's metal, cerrosafe, cerrolow)
mercury amalgam
| — |
additive (salts including carbonates, nitrates, nitrites, chlorites, hypochlorites)
reducing agent
solvent (glycols and carbonates)
low-melting metal alloy (Wood's metal, Rose's metal, Field's metal, cerrosafe, cerrolow)
mercury amalgam
| — |