Patent

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Patent

Method for producing a substrate coated with multi-layer graphenes

Drawings

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Claims

Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.

7 independent · 24 dependent

1
Independentmulti-layer graphenesorganic compound (pre-baked powdery/particulate material)substrate coated with multi-layer graphenes
A method for producing a substrate coated with multi- layer graphenes, comprising laminating, on surface of a substrate, multi-layer graphenes from a mass of multi-layer graphe n es, wherein the mass of multi-layer graphenes is an aggregation having a three-dimensional shape of many discrete multi-layer graphenes each of which is vapor phase grown, without using a catalytic eﬀect of metal, approximately radially or approximately vertically to a plane or spherical surface in a three-dimensional space without being laminated to each other, and the thicknesses of the multi-layer graphenes are in the range of 0.34 nm to 100 nm; and wherein the mass of multi-laver graphenes is vroduced by a method comprising: preparing a powdery and/or particulate material of an organic compound pre-baked at a temperature of 1000 0C or lower, to an extent of containing remaining hydrogen; charging the powdery and/or particulate material in a closed vessel made of a heat- resistant material: and subjecting the powdery and/or particulate material together with the vessel to hot isostatic pressing treatment using a compressed gas atmosphere, wherein a maximum temperature in the hot isostatic pressing treatment is 900 0C or more and lower than 2000 *C, and the maximum temperature in the hot isostatic pressing treatment is higher than the pre-baking temperature. 2 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 ﬁled Response to ﬁnal Oﬃce Action dated April 1,
1. 2
  Dependent← claim 1multi-layer graphenes
  The production method of Claim 1, wherein the mass of multi-layer graphenes is an isotropic cluster of multi-layer graphenes composed of aggregates in such a state that discrete multi-layer graphenes extend approximately radially from the inside toward the outside.
2. 3
  Dependent← claim 1multi-layer graphenes
  (P reviously presented): The production method of Claim 1, wherein the multi- layer graphenes constituting the mass of multi-layer graphenes have a thickness of from 0.34 to 10 nm.
3. 4
  Dependent← claim 1multi-layer graphenes
  The production method of Claim 1, wherein the lamination is carried out by rubbing the surface of the substrate with the mass of multi-layer graphenes. withdrawn
4. 5
  Dependent← claim 1multi-layer graphenes
  The production method of Claim 1, wherein the lamination is carried out by bringing the surface of the substrate into contact with a dispersion of multi-layer graphenes prepared from the mass of multi-layer graphenes and then removing a solvent from the surface of the substrate. withdrawn
5. 6
  Dependent← claim 1multi-layer graphenes
  The production method of Claim 1, wherein the lamination is carried out by dip-coating of the surface of the substrate with a dispersion of multi-layer graphenes prepared from the mass of multi-layer graphenes. 3 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 f il ed Response to ﬁnal Oﬃce Action dated withdrawn
6. 7
  Dependent← claim 1multi-layer graphenes
  The production method of Claim 1, wherein the lamination is carried out by spray-coating of the surface of the substrate with a dispersion of multi-layer graphenes prepared from the mass of multi-layer graphenes. withdrawn
7. 10
  Dependent← claim 1multi-layer graphenessubstrate coated with multi-layer graphenes
  The production method of Claim 1, wherein a thickness of the layer of the multi-layer graphenes on t he substrate coated with multi-layer graphenes is from 0.5 to 10000 nm.
8. 11
  Dependent← claim 1multi-layer graphenessubstrate (resin film, glass, metal foil, paper, glassy carbon, sapphire, non-woven fabric)substrate coated with multi-layer graphenes
  The production method of Claim 1, wherein the substrate is a resin ﬁlm made of a resin selected from a polyester resin, an acrylic resin, a polystyrene resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin and a polytetraﬂuoroethylene resin; a glass substrate coated on its surface with a resin selected from a polyester resin, an acrylic resin, a polystyrene resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin and a polytetraﬂuoroethylene resin or a resin mixture of at least two t hereof; a metal foil, metal sheet or metal ﬁlm made of a metal selected from copper, nickel, iron, aluminum and titanium; paper; a glassy carbon substrate; a sapphire substrate; or a non-woven fabric made of a resin ﬁber, wherein the resin of the ﬁber is selected from aromatic polyamide resin, aromatic polyimide resin and polyester resin.
9. 22
  Dependent← claim 1multi-layer graphenes
  The production method of claim 1, wherein each of the discrete multi-layer graphenes is in a state of being grown, in the direction of the "a" axis of the graphite crystal, approximately vertically to a plane or spherical surface, and the discrete multi- layer graphenes cover the plane surface and the spherical surface to be in a ﬁlm-like form.
10. 23
  Dependent← claim 1multi-layer graphenes
  The production method of claim 1, wherein the discrete multi-layer graphenes are in a state of being grown approximately radially from the center toward the outside of the ﬁber in the direction of "a" axis of the graphite crystal, and the multi- layer graphenes are connected to form a ﬁbrous mass.
11. 31
  Dependent← claim 1multi-layer graphenes
  The method of claim 1, wherein: the thicknesses of the multi-layer graphenes are in the range of 0.34 nm to 3.5 nm. 13
12
Independent
canceled
13
Independentmulti-layer graphenessubstrate coated with multi-layer graphenes
A method for producing a substrate coated with multi-layer graphenes, wherein the substrate coated with multi-layer graphenes has a pattern of thick and thin layers of multi-layer graphenes, said method comprises: preparing a transfer mold provided, on its surface, with convex and concave portions coinciding with the pattern, overlapping a back surface of the substrate over the surface of the transfer mold, and rubbing on the surface of the substrate multi-layer graphenes from a mass of multi-layer graphenes, wherein the mass of multi-layer graphenes is an aggregation having a three-dimensional shape of many discrete multi-layer graphenes each of which is vapor phase grown, without using a catalytic eﬀect of metal, radially or approximately vertically to a plane or spherical surface in a three-dimensional space without being laminated to each other, and the thicknesses of the multi-layer graphenes are in the range of 0.34 n m to 100 n m; and wherein the mass of multi-laver graohenes is produced by a method comorisina: preparing a powdery and/or particulate material of an organic comuound ore-baked at a temperature of 1000 0C or lower, to an extent of containing remaining hydrogen: charging the powdery and/or particulate material in a closed vessel made of a heat- resistant material; and subjecting the powdery and/or particulate material together with the vessel to hot isostatic pressing treatment using a compressed gas atmosphere, wherein a maximum temoerature in the hot isostatic pressing treatment is 900 0C or more and lower than 2000 0C. and the maximum temperature in the hot isostatic pressing treatment is higher than the pre-baking temperature. 6 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 ﬁled Response to ﬁnal Oﬃce Action dated withdrawn
14
Independentmulti-layer graphenesorganic compound (pre-baked powdery/particulate material)substrate coated with multi-layer graphenes
A method for producing a substrate coated with multi- layer graphenes, comprising laminating, on surface of a substrate, multi-layer graphenes from a mass of multi-layer graphenes, and then pressing the surface of the substrate, wherein the mass of multi-layer graphenes is an aggregation having a three-dimensional shape of many discrete multi-layer graphenes, each of which is vapor phase grown, without using a catalytic eﬀect of metal, approximately radially or approximately vertically to a plane or spherical surface in a three-dimensional space without being laminated to each other, and SVG 13698796.06-25-2015.IBCSJRPHPXXIFW3.CLM.6.11.2041.1240.2212.1285.svg 0.15 0.57 Chemistry Black and white the thicknesses of the multi-layer graphenes are in the range of 0.34 n m to 100 wherein the mass of multi-laver graphenes is produced by a method comprising: preparing a bowderv and/or narticulate material of an organic compound pre-baked at a temperature of 1000 0C or lower, to an extent of containing remaining hydrogen; chargina the powdery and/or particulate material in a closed vessel made of a heat- resistant material; and subiecting the powdery and/or particulate material together with the vessel to hot isostatic pressing treatment using a compressed gas atmosphere, wherein a maximum temperature in the hot isostatic pressing treatment is 900 0C or more and lower than 2000 0C, and the maximum temperature in the hot isostatic pressing treatment is hiaher than the pre-baking temperature.
1. 15
  Dependent← claim 14multi-layer graphenes
  The production method of Claim 14, wherein the lamination is carried out by spray-coating of the surface of the substrate with a dispersion of multi-layer graphenes, a liquid of pulverized multi-layer graphenes or a dispersion of residual graphenes which are prepared from a mass of multi-layer graphenes. 7 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 f iled Response to ﬁnal Oﬃce Action dated withdrawn
2. 18
  Dependent← claim 14multi-layer graphenessubstrate (resin film, glass, metal foil, paper, glassy carbon, sapphire, non-woven fabric)substrate coated with multi-layer graphenes
  The production method of Claim 14, wherein the substrate is a resin ﬁlm made of a resin selected from a polyester resin, an acrylic resin, a polystyrene resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin and a polytetraﬂuoroethylene resin; a glass substrate coated on its surface with a 9 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 f il ed Response to ﬁnal Oﬃce Action dated resin selected from a polyester resin, an acrylic resin, a polystyrene resin, a polycarbonate resin, a polypropylene resin, a polyethylene resin, a polyvinyl chloride resin and a polytetraﬂuoroethylene resin or a resin mixture of at least two thereof; a metal foil, metal sheet or metal ﬁlm made of a metal selected from copper, nickel, iron, aluminum and titanium; paper; a glassy carbon substrate; a sapphire substrate; or a non-woven fabric made of a resin ﬁber, wherein the resin of the ﬁber is selected from aromatic polyamide resin, aromatic polyimide resin and polyester resin
3. 19
  Dependent← claim 14multi-layer graphenes
  The production method of Claim 14, wherein the lamination is carried out by a coating method selected from the group consisting of dip coating, spin coating, die coating spray coating, ink jet printing, printing using a dispenser, ﬂexographic printing (letterpress printing), oﬀset printing (planographi c printing), gravure printing (intaglio printing), screen printing, ele c trophotography, heat transfer, laser transfer, slit coating, bar coating, blade coating, melt extrusion molding method in combination of a resin and an additive, inﬂation method, T die method, ﬂat die method, solvent casting method, calendaring method, stretching method, multilayer processing method, co-extrusion method, co-extrusion by inﬂation method, multimanifold method, laminating method, extrusion-laminating method, laminating method using an adhesive, wet laminating method, dry laminating method, hot-melt laminating method, heat-seal method, external heating method, internal heating method, ion, ion plating, and sputtering. U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 ﬁled Response to f in al Oﬃce Action dated
4. 20
  Dependent← claim 14
  The production method of Claim 14, wherein the pressing is carried out by a method selected from the group consisting of cold rolling, hot rolling, roll press, hot press, and hot roll press.
5. 25
  Dependent← claim 14multi-layer graphenes
  The production method of claim 14, wherein the mass of multi-layer graphenes is an isotropic cluster of multi-layer graphenes composed of aggregates in such a state that discrete multi-layer graphenes extend approximately radially from the inside toward the outside.
6. 26
  Dependent← claim 14multi-layer graphenes
  The production method of claim 14, wherein each of the discrete multi-layer graphenes is in a state of being grown, in the direction of the "a " axis of the graphite crystal, approximately vertically to a plane or spherical surface, and the discrete multi-layer graphenes cover the plane surface and the spherical surface to be in a ﬁlm-like fo rm.
7. 27
  Dependent← claim 14multi-layer graphenes
  The production method of claim 14, wherein the discrete multi-layer graphenes are in a state of being grown approximately radially from the center toward the outside of the ﬁber in the direction of "a" axis of the graphite crystal, and the discrete multi-layer graphenes are connected to form a ﬁbrous mass.
8. 29
  Dependent← claim 14
  The production method of claim 14, wherein the pressing step comprises feeding the substrate to a roll press under heating and/or a hot press, wherein the heating temperature of the roll press is 70 0 C to 300 0C, the press load of the roll press is 1 N to 100000 N, the feeding speed to the roll press is 0.1 cm/sec to 10 cm/sec, the heating temperature of the hot press is 70 ° C to 300 *C, the press load of the hot press is 1 N to 5000000 N, and the pressing t ime of the hot press is 10 se c to 10 m in.
9. 30
  Dependent← claim 14substrate (resin film, glass, metal foil, paper, glassy carbon, sapphire, non-woven fabric)
  The production method of Claim 14, wherein the substrate is a resin ﬁlm having a -electron bond, or a non-woven fabric made of a resin ﬁber, wherein the resin of the ﬁber has a -electron bond.
16
Independentmulti-layer graphenesorganic compound (pre-baked powdery/particulate material)substrate coated with multi-layer graphenes
A method for producing a substrate coated with multi-layer graphenes, comprising laminating, on surface of a substrate, multi-layer graphenes from a mass of multi-layer graphe n es, wherein the lamination is carried out by single-ﬂuid spray-coating of the surface of the substrate with a dispersion of multi-layer graphenes, a liquid of pulverized multi-layer graphenes or a dispersion of residual graphenes, which are prepared from a mass of multi-layer graphenes, wherein the mass of multi-layer graphenes is an aggregation having a three-dimensional shape of many discrete multilayer graphenes, each of which is vapor phase grown, without using a catalytic eﬀect of metal, approximately radially or approximately vertically to a plane or spherical surface in a three-dimensional space without being laminated to each other, and the thicknesses of the multi-layer graphenes are in the range of 0.34 n m to 100 nm; and wherein the mass of multi-laver graphenes is nroduced by a method comprising: preparing a powdery and/or particulate material of an organic compound pre-baked at a temperature of 1000 0C or lower, to an extent of containing remaining hydrogen charging the powdery and/or particulate material in a closed vessel made of a heat- resistant material: and subjecting the powdery and/or particulate material together with the vessel to hot isostatic pressing treatment using a compressed gas atmosphere, wherein a maximum temperature in the hot isostatic pressing treatment is 900 0C or more and lower than 2000 0C. and the maximum temperature in the hot isostatic pressing treatment is higher than the pre-baking temperature. 8 U.S. Patent Application Serial No.: 13/698,796 Response under 37 CFR 1.116 ﬁled Response to f in al Oﬃce Action dated withdrawn
17
Independentmulti-layer graphenesorganic compound (pre-baked powdery/particulate material)substrate coated with multi-layer graphenes
A substrate coated with multi-layer graphenes, said substrate is produced by laminating, on surface of a substrate, multi-layer graphenes from a mass of multi-layer graphenes, wherein the mass of multi-layer graphenes is an aggregation having a three-dimensional shape of many discrete multi-layer graphenes each of which is vapor phase grown, without using a catalytic eﬀect of metal, approximately radially or approximately vertically to a plane or spherical surface in a three-dimensional space without being laminated to each other, and the thicknesses of the multi-layer graphenes are in the range of 0.34 nm to 100 nm; and wherein the mass of multi-layer graphenes is produced by a method comprising: preparing a powderv and/or particulate material of an organic compound pre-baked at a temperature of 1000 *C or lower, to an extent of containing remaining hydrogen; charging the powdery and/or particulate material in a closed vessel made of a heat- resistant material; and subjecting the powdery and/or particulate material together with the vessel to hot isostatic pressing treatment using a compressed gas atmosphere, wherein a maximum temperature in the hot isostatic pressing treatment is 900 *C or more and lower than 2000 0C, and the maximum temperature in the hot isostatic pressing treatment is higher than the pre-baking temperature. withdrawn
21
Independent
canceled

Device structures

Layer stacks claimed or described, ordered top of device to substrate.

substrate coated with multi-layer graphenes

multi-layer graphenescoating

substrate (resin film, glass, metal foil, paper, glassy carbon, sapphire, non-woven fabric)substrate

Materials

Materials described outside the worked examples.

multi-layer graphenes

Coating Material

organic compound (pre-baked powdery/particulate material)

Precursor

Process steps

Additional fabrication and treatment steps described in the patent.

Hot Isostatic Pressing

Step 1

Temperature

900, 2000°C

Ambient

compressed gas atmosphere

Reported properties

Performance values and ranges asserted in the specification or claims.

Property	Value	Material
Thickness	0.34–100 nm	—
Thickness

Method for producing a substrate coated with multi-layer graphenes | Matter42 Literature