Patent
US 11,339,054Continuous Process and Apparatus for Producing Graphene
Aruna Zhamu, B or Z. Jang
US
Copyright © 2026 Matter42. All rights reserved.
Patent
Atlas literature
Patent
US 11,339,054Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(A) A flow chart showing the most commonly used prior art process of producing highly oxidized graphite and graphene oxide sheets that entails tedious …
FIG. 2 A diagram to illustrate the "finite volume " or "finite element" strategy wherein a reacting mass in a bulk reactor is conceptually divided into a large …
FIG. 3(B) Schematic of a finite volume-based reactor used to produce GIC/GO and graphene sheets.
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 isolated graphene sheets or a precursor material to said isolated graphene sheets, said method comprising: a) providing a reacting slurry containing a mixture of (i) particles of a graphite or carbon material and (ii) an intercalant, an oxidizing agent, or a combination of an intercalant and an oxidizing agent, wherein said intercalating agent or oxidizing agent is selected from an acid, a lithium salt, a sodium salt, lithium perchlorate, sodium perchlorate, potassium perchlorate, potassium manganese, lithium manganese, sodium manganese, hydrogen peroxide, a metal halide or a combination thereof, wherein said acid is selected from nitric acid, carboxylic acid, phosphoric acid, sorbic acid, acetic acid, or a combination thereof, wherein * -the metal halide is selected from M C₁ 2 (M = Zn, Ni, Cu, Mn), MC l 3 (M=Al, Fe, Ga), or MC l 4 (M = Zr, Pt); b) providing a pipe having a plurality of flow channels to accommodate said reacting slurry, wherein at least one of said flow channels has an internal wall surface and a volume (having a length and a cross-sectional area having a diameter or a width and a height) and a total internal wall surface area-to-volume ratio from 10 to 4,000 cm⁻¹; c) moving said reacting slurry continuously or intermittently through said at least one or a plurality of flow channels, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material as a precursor material, and d) circulating the reacting slurry through at least one or a plurality of flow channels multiple times, enabling reactions between the graphite or carbon particles and the intercalant and/or oxidant to occur substantially inside the flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Currently amended
The method of claim 1, further comprising a step of converting said precursor material to isolated graphene sheets. Original
The method of claim 1, wherein said one or a plurality of flow channels are in thermal contact with temperature control means to regulate a temperature of said reacting slurry. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 mm to 40 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 cm to 20 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters and a diameter, width, or height from 2.5 cm to 13 cm or from 1 inch to inches. Original
The method of claim 1, wherein said graphite intercalation compound (GIC) contains Stage- 1 GIC or said oxidized graphite or carbon has an oxygen content from 20 to 50% by weight. Original
The method of claim 1, wherein said graphite or carbon material is selected from natural graphite, synthetic graphite, amorphous graphite, highly oriented pyrolytic graphite, mesocarbon microbead, graphitized mesophase carbon, needle coke, carbon fiber, graphite fiber, carbon nanofiber, graphitic nanofiber, graphite fluoride, chemically modified graphite, expanded graphite, or a combination thereof. Original
The method of claim 1, wherein said step of moving said reacting slurry includes circulating said reacting slurry through said at least one or a plurality of flow channels multiple times, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Original
Canceled
Canceled
Canceled
Materials described outside the worked examples.
graphite or carbon material
intercalant or oxidizing agent
graphite intercalation compound (GIC)
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
oxygen content of oxidized graphite or oxidized carbon material (Stage-1 GIC precursor) | 20–50 wt% | oxidized graphite or oxidized carbon material |
Thickness | 1000000–400000000 nm |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 11,339,054Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(A) A flow chart showing the most commonly used prior art process of producing highly oxidized graphite and graphene oxide sheets that entails tedious …
FIG. 2 A diagram to illustrate the "finite volume " or "finite element" strategy wherein a reacting mass in a bulk reactor is conceptually divided into a large …
FIG. 3(B) Schematic of a finite volume-based reactor used to produce GIC/GO and graphene sheets.
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 isolated graphene sheets or a precursor material to said isolated graphene sheets, said method comprising: a) providing a reacting slurry containing a mixture of (i) particles of a graphite or carbon material and (ii) an intercalant, an oxidizing agent, or a combination of an intercalant and an oxidizing agent, wherein said intercalating agent or oxidizing agent is selected from an acid, a lithium salt, a sodium salt, lithium perchlorate, sodium perchlorate, potassium perchlorate, potassium manganese, lithium manganese, sodium manganese, hydrogen peroxide, a metal halide or a combination thereof, wherein said acid is selected from nitric acid, carboxylic acid, phosphoric acid, sorbic acid, acetic acid, or a combination thereof, wherein * -the metal halide is selected from M C₁ 2 (M = Zn, Ni, Cu, Mn), MC l 3 (M=Al, Fe, Ga), or MC l 4 (M = Zr, Pt); b) providing a pipe having a plurality of flow channels to accommodate said reacting slurry, wherein at least one of said flow channels has an internal wall surface and a volume (having a length and a cross-sectional area having a diameter or a width and a height) and a total internal wall surface area-to-volume ratio from 10 to 4,000 cm⁻¹; c) moving said reacting slurry continuously or intermittently through said at least one or a plurality of flow channels, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material as a precursor material, and d) circulating the reacting slurry through at least one or a plurality of flow channels multiple times, enabling reactions between the graphite or carbon particles and the intercalant and/or oxidant to occur substantially inside the flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Currently amended
The method of claim 1, further comprising a step of converting said precursor material to isolated graphene sheets. Original
The method of claim 1, wherein said one or a plurality of flow channels are in thermal contact with temperature control means to regulate a temperature of said reacting slurry. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 mm to 40 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 cm to 20 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters and a diameter, width, or height from 2.5 cm to 13 cm or from 1 inch to inches. Original
The method of claim 1, wherein said graphite intercalation compound (GIC) contains Stage- 1 GIC or said oxidized graphite or carbon has an oxygen content from 20 to 50% by weight. Original
The method of claim 1, wherein said graphite or carbon material is selected from natural graphite, synthetic graphite, amorphous graphite, highly oriented pyrolytic graphite, mesocarbon microbead, graphitized mesophase carbon, needle coke, carbon fiber, graphite fiber, carbon nanofiber, graphitic nanofiber, graphite fluoride, chemically modified graphite, expanded graphite, or a combination thereof. Original
The method of claim 1, wherein said step of moving said reacting slurry includes circulating said reacting slurry through said at least one or a plurality of flow channels multiple times, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Original
Canceled
Canceled
Canceled
Materials described outside the worked examples.
graphite or carbon material
intercalant or oxidizing agent
graphite intercalation compound (GIC)
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
oxygen content of oxidized graphite or oxidized carbon material (Stage-1 GIC precursor) | 20–50 wt% | oxidized graphite or oxidized carbon material |
Thickness | 1000000–400000000 nm |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 11,339,054Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(A) A flow chart showing the most commonly used prior art process of producing highly oxidized graphite and graphene oxide sheets that entails tedious …
FIG. 2 A diagram to illustrate the "finite volume " or "finite element" strategy wherein a reacting mass in a bulk reactor is conceptually divided into a large …
FIG. 3(B) Schematic of a finite volume-based reactor used to produce GIC/GO and graphene sheets.
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 isolated graphene sheets or a precursor material to said isolated graphene sheets, said method comprising: a) providing a reacting slurry containing a mixture of (i) particles of a graphite or carbon material and (ii) an intercalant, an oxidizing agent, or a combination of an intercalant and an oxidizing agent, wherein said intercalating agent or oxidizing agent is selected from an acid, a lithium salt, a sodium salt, lithium perchlorate, sodium perchlorate, potassium perchlorate, potassium manganese, lithium manganese, sodium manganese, hydrogen peroxide, a metal halide or a combination thereof, wherein said acid is selected from nitric acid, carboxylic acid, phosphoric acid, sorbic acid, acetic acid, or a combination thereof, wherein * -the metal halide is selected from M C₁ 2 (M = Zn, Ni, Cu, Mn), MC l 3 (M=Al, Fe, Ga), or MC l 4 (M = Zr, Pt); b) providing a pipe having a plurality of flow channels to accommodate said reacting slurry, wherein at least one of said flow channels has an internal wall surface and a volume (having a length and a cross-sectional area having a diameter or a width and a height) and a total internal wall surface area-to-volume ratio from 10 to 4,000 cm⁻¹; c) moving said reacting slurry continuously or intermittently through said at least one or a plurality of flow channels, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material as a precursor material, and d) circulating the reacting slurry through at least one or a plurality of flow channels multiple times, enabling reactions between the graphite or carbon particles and the intercalant and/or oxidant to occur substantially inside the flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Currently amended
The method of claim 1, further comprising a step of converting said precursor material to isolated graphene sheets. Original
The method of claim 1, wherein said one or a plurality of flow channels are in thermal contact with temperature control means to regulate a temperature of said reacting slurry. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 mm to 40 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 cm to 20 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters and a diameter, width, or height from 2.5 cm to 13 cm or from 1 inch to inches. Original
The method of claim 1, wherein said graphite intercalation compound (GIC) contains Stage- 1 GIC or said oxidized graphite or carbon has an oxygen content from 20 to 50% by weight. Original
The method of claim 1, wherein said graphite or carbon material is selected from natural graphite, synthetic graphite, amorphous graphite, highly oriented pyrolytic graphite, mesocarbon microbead, graphitized mesophase carbon, needle coke, carbon fiber, graphite fiber, carbon nanofiber, graphitic nanofiber, graphite fluoride, chemically modified graphite, expanded graphite, or a combination thereof. Original
The method of claim 1, wherein said step of moving said reacting slurry includes circulating said reacting slurry through said at least one or a plurality of flow channels multiple times, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Original
Canceled
Canceled
Canceled
Materials described outside the worked examples.
graphite or carbon material
intercalant or oxidizing agent
graphite intercalation compound (GIC)
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
oxygen content of oxidized graphite or oxidized carbon material (Stage-1 GIC precursor) | 20–50 wt% | oxidized graphite or oxidized carbon material |
Thickness | 1000000–400000000 nm |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 11,339,054Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(A) A flow chart showing the most commonly used prior art process of producing highly oxidized graphite and graphene oxide sheets that entails tedious …
FIG. 2 A diagram to illustrate the "finite volume " or "finite element" strategy wherein a reacting mass in a bulk reactor is conceptually divided into a large …
FIG. 3(B) Schematic of a finite volume-based reactor used to produce GIC/GO and graphene sheets.
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 isolated graphene sheets or a precursor material to said isolated graphene sheets, said method comprising: a) providing a reacting slurry containing a mixture of (i) particles of a graphite or carbon material and (ii) an intercalant, an oxidizing agent, or a combination of an intercalant and an oxidizing agent, wherein said intercalating agent or oxidizing agent is selected from an acid, a lithium salt, a sodium salt, lithium perchlorate, sodium perchlorate, potassium perchlorate, potassium manganese, lithium manganese, sodium manganese, hydrogen peroxide, a metal halide or a combination thereof, wherein said acid is selected from nitric acid, carboxylic acid, phosphoric acid, sorbic acid, acetic acid, or a combination thereof, wherein * -the metal halide is selected from M C₁ 2 (M = Zn, Ni, Cu, Mn), MC l 3 (M=Al, Fe, Ga), or MC l 4 (M = Zr, Pt); b) providing a pipe having a plurality of flow channels to accommodate said reacting slurry, wherein at least one of said flow channels has an internal wall surface and a volume (having a length and a cross-sectional area having a diameter or a width and a height) and a total internal wall surface area-to-volume ratio from 10 to 4,000 cm⁻¹; c) moving said reacting slurry continuously or intermittently through said at least one or a plurality of flow channels, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material as a precursor material, and d) circulating the reacting slurry through at least one or a plurality of flow channels multiple times, enabling reactions between the graphite or carbon particles and the intercalant and/or oxidant to occur substantially inside the flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Currently amended
The method of claim 1, further comprising a step of converting said precursor material to isolated graphene sheets. Original
The method of claim 1, wherein said one or a plurality of flow channels are in thermal contact with temperature control means to regulate a temperature of said reacting slurry. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 mm to 40 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a diameter, width, or height from 1 cm to 20 cm. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters. Original
The method of claim 1, wherein said one or a plurality of flow channels have a length from 1 meter to 1,000 meters and a diameter, width, or height from 2.5 cm to 13 cm or from 1 inch to inches. Original
The method of claim 1, wherein said graphite intercalation compound (GIC) contains Stage- 1 GIC or said oxidized graphite or carbon has an oxygen content from 20 to 50% by weight. Original
The method of claim 1, wherein said graphite or carbon material is selected from natural graphite, synthetic graphite, amorphous graphite, highly oriented pyrolytic graphite, mesocarbon microbead, graphitized mesophase carbon, needle coke, carbon fiber, graphite fiber, carbon nanofiber, graphitic nanofiber, graphite fluoride, chemically modified graphite, expanded graphite, or a combination thereof. Original
The method of claim 1, wherein said step of moving said reacting slurry includes circulating said reacting slurry through said at least one or a plurality of flow channels multiple times, enabling reactions between said graphite or carbon particles and said intercalant and/or oxidant to occur substantially inside said flow channels to form a Stage- 1 graphite intercalation compound (GIC) or oxidized graphite or oxidized carbon material having an oxygen content from 20% to 50% by weight. Original
Canceled
Canceled
Canceled
Materials described outside the worked examples.
graphite or carbon material
intercalant or oxidizing agent
graphite intercalation compound (GIC)
Additional fabrication and treatment steps described in the patent.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
oxygen content of oxidized graphite or oxidized carbon material (Stage-1 GIC precursor) | 20–50 wt% | oxidized graphite or oxidized carbon material |
Thickness | 1000000–400000000 nm |
Related documents with shared materials, methods, properties, or citations.
oxidized graphite or oxidized carbon material
reacting slurry
isolated graphene sheets
pristine graphene
graphene fluoride
| — |
Thickness | 1–20 cm | — |
Thickness | 2.5–13 cm | — |
Temperature | 200–1500 °C | — |
Duration | 15–300 s | — |
Duration | 15–60 seconds | — |
Duration | 4–120 hours | — |
Temperature | 800–1050 °C | — |
Duration | 1–2 hours | — |
Temperature | 800–1100 °C | — |
Temperature | 950–1050 °C | — |
Thickness | ≥ 0.6 nm | — |
Thickness | 10–4000 cm | — |
oxidized graphite or oxidized carbon material
reacting slurry
isolated graphene sheets
pristine graphene
graphene fluoride
| — |
Thickness | 1–20 cm | — |
Thickness | 2.5–13 cm | — |
Temperature | 200–1500 °C | — |
Duration | 15–300 s | — |
Duration | 15–60 seconds | — |
Duration | 4–120 hours | — |
Temperature | 800–1050 °C | — |
Duration | 1–2 hours | — |
Temperature | 800–1100 °C | — |
Temperature | 950–1050 °C | — |
Thickness | ≥ 0.6 nm | — |
Thickness | 10–4000 cm | — |
oxidized graphite or oxidized carbon material
reacting slurry
isolated graphene sheets
pristine graphene
graphene fluoride
| — |
Thickness | 1–20 cm | — |
Thickness | 2.5–13 cm | — |
Temperature | 200–1500 °C | — |
Duration | 15–300 s | — |
Duration | 15–60 seconds | — |
Duration | 4–120 hours | — |
Temperature | 800–1050 °C | — |
Duration | 1–2 hours | — |
Temperature | 800–1100 °C | — |
Temperature | 950–1050 °C | — |
Thickness | ≥ 0.6 nm | — |
Thickness | 10–4000 cm | — |
oxidized graphite or oxidized carbon material
reacting slurry
isolated graphene sheets
pristine graphene
graphene fluoride
| — |
Thickness | 1–20 cm | — |
Thickness | 2.5–13 cm | — |
Temperature | 200–1500 °C | — |
Duration | 15–300 s | — |
Duration | 15–60 seconds | — |
Duration | 4–120 hours | — |
Temperature | 800–1050 °C | — |
Duration | 1–2 hours | — |
Temperature | 800–1100 °C | — |
Temperature | 950–1050 °C | — |
Thickness | ≥ 0.6 nm | — |
Thickness | 10–4000 cm | — |