Large Scale Graphene Production Using a Radio-Frequency Catalytic Chemical Vapor Deposition Method

Technology Overview

This technology is a method for synthesizing sheets of graphene, each sheet being a single layer of planar carbon having the elemental structure of graphite. The method relies upon catalytic chemical vapor deposition, using acetylene as a carbon source. A thin catalyst layer of iron and cobalt on a high surface area magnesium oxide support is prepared upon a graphite susceptor. This reaction bed is placed in a furnace and is heated by radio frequency (RF) induction. When the synthesis temperature of about 1000 degrees C is reached, acetylene gas is flowed over the catalyst-coated graphite
susceptor. The acetylene decomposes and some of the carbon forms graphene sheets, typically between 1-5 layers thick, in areas of about 100 nanometers in diameter.

Benefits

• Simple process: A simple RF furnace and readily available staring materials can be used
• Potential for low cost production: The equipment and materials are relatively inexpensive

Potential Applications

• Fuel cells
• Electrodes for batteries and supercapacitors
• Solar cells
• Electronics, such as field effect transistors
• Electron field emission cathodes
• Chemical detectors
• Composite materials

 

Keywords: fullerenes, graphite nanoplatelets, graphitic sheet, graphene, composites, electrodes, chemical vapor deposition, catalytic chemical vapor deposition, rf heater, field effect transistor
Inventors: Alexandru S. Biris, Enkeleda Dervishi