General Graphene Corporation

Gregory Erickson

James Vig Sherrill

A method of making 2D material such as graphene includes introducing a purge gas into a gas confining space within a reaction chamber to purge the gas confining space of oxygen; introducing a donor gas into the gas confining space within the reaction chamber; moving a forming layer within the gas confining space within the reaction chamber when the donor gas is within the gas confining space; and heating the forming layer within the gas confining space to a temperature sufficient to form 2D material while the gas confining space is open to a surrounding atmosphere.

Methods for producing 2D materials by moving forming layers disposed on carriers through a reaction chamber open to the atmosphere

A 2D material such as graphene is produced on a forming sheet disposed on a carrier and exposed to a donor gas within a furnace. A first furnace surface is disposed immediately adjacent to and spaced apart from the forming sheet to define a volume. A purge gas is used to purge the volume of undesirable molecules, such as oxygen, and then a donor gas is introduced into the volume to supply an element or molecule necessary for the formation of a 2D material. Multiple carriers and forming sheets are moved in a train into the furnace during the presence of the donor gas, and each forming sheet is heated to a temperature sufficient to form 2D material on the sheet. The furnace is constructed of a nonreactive material, such as quartz, and the first furnace surface is provided by a quartz plate. Gas passageways and gas ports are formed in the quartz plate with the ports extending through the first furnace surface. The ports are disposed in patterns that facilitate the production of a smooth nonturbulent laminar flow of gas within the volume. As gases are introduced into the furnace, the gases are constrained but they escape and are collected by a surrounding gas chamber. Undesirable gases are purged and desirable gases are maintained in both the furnace and the gas chamber.

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Knoxville, TN, United States of America

Gregory Erickson