Nebraska Patent of the Month – November 2024
Monolith Materials Inc. has developed a groundbreaking method for producing carbon particles with unprecedented precision, efficiency, and application potential. These disk-shaped carbon particles, known as Few Layer Graphene (FLG), possess unique properties that position them at the forefront of next-generation materials for industries ranging from energy storage to advanced manufacturing.
At the core of this innovation is an advanced gas-phase process that operates within a reactor at temperatures exceeding 2400°C. A hydrocarbon gas is combined with an inert gas, such as hydrogen, and subjected to extreme heat to form a plasma. This high-energy environment transforms the gas mixture into a heated state, where a second hydrocarbon source is injected, resulting in the formation of ultra-fine carbon particles. The resulting disks are less than 3 micrometers in diameter, with a height of less than 0.05 micrometers, achieving an aspect ratio optimized for performance.
What sets Monolith’s FLG apart is not just their size and shape but their versatility and affordability. These particles are created using natural gas as a primary feedstock, which reduces production costs while ensuring scalability. Furthermore, their unique disk structure enhances their application in conductive inks, battery electrodes, polymer composites, and elastomers, unlocking possibilities for improved performance and durability across numerous industries.
This method also represents a step forward in sustainable manufacturing. By leveraging hydrogen-rich environments and efficient electrical energy sources, Monolith’s process minimizes waste and maximizes material output, aligning with global efforts to lower carbon footprints.
With this innovation, Monolith Materials Inc. is reshaping the landscape of material science, providing industries with cost-effective, high-performance carbon particles that could redefine the limits of technology and sustainability.
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