Graphite Electrodes for Continuous Graphene Synthesis and Lower Contamination
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Solution Overview
Problem
Existing methods for graphene production face challenges in industrial scalability due to the degradation of quartz tubes and copper wool electrodes, leading to high costs and metal contamination, and require disassembly for each batch, hindering continuous production.
Innovation Solution
A device and method for continuous graphene synthesis using electrodes made from materials like copper, brass, stainless steel, and graphite, with independent movement and electrical current directions, and venting to prevent contamination, allowing for continuous processing and reducing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If quartz tubes are used for joule heating, then the carbon source can be heated to high temperatures, but the quartz tubes are degraded and contaminated during the process, requiring disposal after single use
Solution Approach 1:
The patent introduces a graphite electrode as an intermediary component that serves both as an electrode for applying electrical current and as a container for the carbon source. This graphite electrode replaces the quartz tube as the heating chamber, eliminating the degradation issue while maintaining the high temperature heating capability needed for graphene synthesis.
Solution Approach 2:
The patent changes the material parameter of the heating chamber from quartz to graphite, which has superior thermal stability and electrical conductivity. This parameter change allows the system to maintain high temperatures for joule heating without the degradation that occurs with quartz tubes.
2Power
If copper wool electrodes are used, then electrical current can be applied to heat the carbon source, but the electrodes are degraded by the process, increasing production costs
Solution Approach 1:
The patent changes the electrode material from copper wool to graphite, which has better thermal stability and resistance to degradation at high temperatures. This parameter change maintains the electrical current application capability while preventing the electrode degradation that increases production costs.
Solution Approach 2:
The patent uses graphite, which has composite properties combining electrical conductivity, thermal stability, and chemical inertness at high temperatures. This composite material properties allow the electrode to withstand the harsh conditions of joule heating without degrading.
3Power
If metal electrodes make direct contact with graphene, then electrical current can be applied, but metal contaminants are added to the graphene powder
Solution Approach 1:
The patent uses graphite as an intermediary electrode material that does not contaminate the graphene product. The graphite electrode applies electrical current while maintaining chemical inertness toward the carbon source, preventing metal contamination that would occur with copper or brass electrodes.
Solution Approach 2:
The patent changes the electrode material composition from metal (copper, brass) to graphite, which has different chemical properties that prevent contamination. This parameter change maintains electrical conductivity while eliminating the harmful metal contamination effect.
4Productivity
If batch processing is used, then graphene can be produced, but the device must be assembled and disassembled between batches, preventing continuous production
Solution Approach 1:
The patent designs a dynamic system where the graphite electrode can be continuously fed with carbon source and continuously discharged with graphene product without disassembly. This dynamic design eliminates the assembly and disassembly time losses inherent in batch processing, enabling continuous production.
Solution Approach 2:
The patent implements continuous useful action by allowing the graphite electrode to remain in place while carbon source is continuously fed in and graphene is continuously discharged out. This eliminates the interruption caused by batch assembly and disassembly, maintaining continuous production capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables low-cost, continuous production of graphene by minimizing tube and electrode degradation, reducing contamination, and enabling large-scale manufacturing without the need for batch-by-batch disassembly.
Implementation Method 1
The device includes at least two electrodes for applying an electrical current through the space for joule heating the carbon source
Data Source
AI summary
Provided herein is a method and a device for continuous synthesis of graphene. The device includes a container having a space for holding a carbon source, wherein the container has an entry opening for receiving the carbon source material, at least two electrodes for applying an electrical current through the space for joule heating the carbon source, wherein the space for joule heating the carbon source is between the at least to electrodes, and a movement component for moving the carbon source, with respect to the container, into the entry opening in a first direction and the at least two electrodes apply the electrical current in a second direction, wherein the first direction is not the same as the second direction.