# US 12,119,133 B2 · Circular few layer graphene

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- Number: US 12,119,133 B2
- Document ID: US12119133B2
- Status: Granted
- Kind: B2
- Application number: 17/817,482
- Filed: 2022-08-04
- Published: 2023-05-18
- Granted: 2024-10-15
- Earliest claimed: 2015-09-09
- Assignees: Monolith Materials, Inc.
- Applicants: Monolith Materials, Inc.
- Inventors: Ned J. Hardman; Roscoe W. Taylor; Peter L. Johnson; Robert J. Hanson
- Web page: https://patentgrep.com/patent/US12119133B2

## CPC

- H01B 1/04: mainly consisting of carbon-silicon compounds, carbon or silicon
- C01B 32/15: Nano-sized carbon materials
- C01B 32/184: Preparation
- C01B 2204/04: Specific amount of layers or specific thickness
- C01B 2204/32: Size or surface area
- C01P 2004/24: Nanoplates, i.e. plate-like particles with a thickness from 1-100 nanometer
- C01P 2004/54: Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension
- C01P 2004/61: Micrometer sized, i.e. from 1-100 micrometer
- C01P 2006/12: Surface area
- C09C 1/44: Carbon
- H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K})
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C09C: TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES (treatment of materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone C04B14/00, C04B18/00, C04B20/00); PREPARATION OF CARBON BLACK {; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS}

## Abstract

Disk shaped fine carbon particles. A fine carbon particle having a diameter of less than 3 microns and a height of less than 0.05 micron substantially in disk form are described. Admixtures with other fine particles are also described.

## Claims

### Claim 1

A method for making a carbon particle, comprising:
(a) loading a hydrocarbon gas into an inert gas to form a gas mixture within a reactor, wherein the gas mixture comprises at least 50% hydrogen by volume;
(b) heating the gas mixture to a temperature of at least 2400° C. to form a heated gas mixture; and
(c) mixing a second hydrocarbon source into the heated gas mixture within the reactor, thereby forming the carbon particle, wherein the carbon particle has a diameter of less than 3 micrometers and a height of less than 0.05 micrometers and is shaped substantially as a disk.

### Claim 2 (depends on 1)

The method of claim 1, wherein (b) comprises heating the gas mixture to a temperature from 2400° C. to 3400° C.

### Claim 3 (depends on 1)

The method of claim 1, wherein the heated gas mixture is a plasma gas injected into an annulus created by two electrodes positioned within the reactor.

### Claim 4 (depends on 1)

The method of claim 1, further comprising using plasma forming electrodes to generate the heated gas mixture.

### Claim 5 (depends on 1)

The method of claim 1, further comprising using a resistive or inductive heater to generate the heated gas mixture.

### Claim 6 (depends on 1)

The method of claim 1, wherein the carbon particle has a diameter to height aspect ratio of at least 4.

### Claim 7 (depends on 6)

The method of claim 6, wherein the diameter to height aspect ratio is at least 10 but less than 200.

### Claim 8 (depends on 6)

The method of claim 6, wherein the diameter to height aspect ratio is between 4 and 150.

### Claim 9 (depends on 1)

The method of claim 1, wherein the hydrocarbon gas is natural gas or methane.

### Claim 10 (depends on 1)

The method of claim 1, wherein (b) comprises using electrical energy.

### Claim 11 (depends on 1)

The method of claim 1, wherein the carbon particle is a few layer graphene.

### Claim 12 (depends on 1)

The method of claim 1, wherein the inert gas comprises nitrogen, hydrogen, or argon.

### Claim 13 (depends on 1)

The method of claim 1, wherein the second hydrocarbon source comprises natural gas or methane.

### Claim 14 (depends on 1)

The method of claim 1, wherein the inert gas is hydrogen.

### Claim 15 (depends on 10)

The method of claim 10, wherein the electrical energy comprises the power output of at least two DC electrodes.