Apparatus and method for bulk production of atomically thin 2-dimensional materials including graphene

Abstract

An apparatus for production of Graphene and similar atomic scale laminar materials by the delamination of a bulk laminar material, such as graphite; comprising: a pump for pumping a fluid being a suspension of solid particles of the bulk laminar material, at a pressure of greater than 1 MPa, along a fluid conduit and against; an impact head having an impact face substantially perpendicular to the trajectory of incoming fluid to form a narrow variable gap. Variation is mediated by pneumatic pressure directly or indirectly in opposition to the force applied to the impact head along the principle axis by, in use, the pressure applied by the fluid. This provides a self-unblocking delamination apparatus maintaining high product quality and consistency. Relatively small variation in gap size being sufficient to avoid blockage, such as occurs by aggregation of large particles or groups of particles in the high shear gap used for delamination.

What is claimed is: 
     
         1 . An apparatus for the production of Graphene and similar atomic scale laminar materials by the delamination of a bulk laminar material; the apparatus comprising:
 a main pump ( 112 ), suitable for pumping a fluid, the fluid being a suspension of solid particles of the bulk laminar material, at a pressure of greater than 1M Pa, in a first direction and along a principle axis towards and in fluid communication with;   core components ( 10 ), the core components comprising:   a fluid conduit ( 12 ) defining a principal axis along which the fluid is pumpable and suitable for conveying said fluid, wherein the fluid conduit is arranged to direct fluid at said pressure from that conduit against;   an impact head ( 16 ) having an impact face ( 28 ) perpendicular or substantially perpendicular to said principal axis and so produce a resultant first force in the first direction; the impact head and the conduit being arranged so that a variable, preferably annular, gap ( 20 ) results between an end ( 24 ) of the conduit proximate to the impact head and the impact head wherein the gap forms a continuous region surrounding the end of the conduit and being substantially coplanar with the impact head; and   wherein,   the apparatus is configured to bias the impact head in a second direction in direct opposition to the fluid in the first direction and to do so with a second force and the impact head ( 16 ) of the apparatus is configured so as to be movable along the principal axis relative to the proximal end ( 24 ) of the conduit so as to vary the gap ( 20 ) and wherein   that movement is a result of the magnitude of first force in opposition to the second force, the second force being the result of a pneumatic pressure directly or indirectly in opposition to the first force exerted on the impact head along the principle axis.   
     
     
         2 . The apparatus of  claim 1 , wherein the impact head comprises at least one of: alumina, silicon nitride, tungsten carbide, silicon carbide, boron nitride, graphite and diamond. 
     
     
         3 . The apparatus of  claim 1 , wherein the impact head comprises a combination of carbon materials. 
     
     
         4 . The apparatus of  claim 3 , wherein the impact head comprises a combination of graphite and diamond materials. 
     
     
         5 . The apparatus of  claim 1 , wherein the impact head comprises a diamond material and is cooled to a temperature of less than 50° C. 
     
     
         6 . The apparatus of  claim 1 , wherein the impact head comprises a diamond material and is cooled to a temperature of less than 10° C. 
     
     
         7 . The apparatus of  claim 1 , further comprising a pressure drop valve downstream of the impact head so as to, in use, maintain a secondary backpressure after the impact head. 
     
     
         8 . The apparatus of  claim 1 , wherein the impact head of the apparatus is freely rotatable about the principal axis. 
     
     
         9 . The apparatus of  claim 1 , wherein the impact head of the apparatus is configured to be rotatable about the principal axis as constrained by a mechanism. 
     
     
         10 . The apparatus of  claim 1 , further comprising a cooler in fluid communication with said fluid conduit and said main pump, such that the suspension to be processed will pass through the cooler and out to the main pump before passing through the core components, the cooler being configured to reduce the temperature of said fluid. 
     
     
         11 . The apparatus of  claim 10 , further comprising a second, lower-pressure, pump in fluid communication with an inlet to the cooler and the outlet of the cooler being in fluid communication with the main pump such that the suspension is first drawn into the second pump, passes through the cooler and out to the main pump before passing through the core components. 
     
     
         12 . The apparatus of  claim 1  wherein the main pump has a reciprocating action configured to inducing a pressure fluctuation in fluid and hence in the magnitude of the first force. 
     
     
         13 . The apparatus of  claim 1  wherein the pneumatic pressure is indirectly in opposition to the first force and exerts the second force to the impact head by means of a mechanical linkage giving a mechanical advantage. 
     
     
         14 . A method for exfoliation of laminar materials to produce atomic scale laminar materials by the delamination of bulk material; the method comprises the steps of:
 providing the apparatus described in  claim 1 ; and   passing through the apparatus a suspension of laminar material in a liquid at a pressure of greater than 1 MPa.   
     
     
         15 . The method of  claim 14 , wherein the fluid that exits the core components is recycled back to the inlet of the main pump optionally via a cooler or a second pump. 
     
     
         16 . The method of  claim 14 , wherein the temperature of the fluid is maintained in the range 30° C. to 80° C. 
     
     
         17 . The method of  claim 14 , where the particles are in the size range 3 μm to 50 μm. 
     
     
         18 . The method of  claim 14 , wherein the laminar material loading in the liquid phase is in the range up to 500 grams per litre (g/l). 
     
     
         19 . A method comprising:
 utilizing the apparatus of  claim 1  for the production of graphene and similar atomic scale laminar materials by the delamination of a bulk laminar material.   
     
     
         20 . A method comprising:
 utilizing the apparatus of  claim 1  for the production of graphene and similar atomic scale laminar materials wherein the solid particles are particles of graphite, hexagonal boron nitride or molybdenum disulphide.