WO2020248048A1 - Apparatuses, methods, and systems for fabricating graphene membranes - Google Patents

Apparatuses, methods, and systems for fabricating graphene membranes Download PDF

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Publication number
WO2020248048A1
WO2020248048A1 PCT/CA2020/050789 CA2020050789W WO2020248048A1 WO 2020248048 A1 WO2020248048 A1 WO 2020248048A1 CA 2020050789 W CA2020050789 W CA 2020050789W WO 2020248048 A1 WO2020248048 A1 WO 2020248048A1
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Prior art keywords
fluid chamber
porous substrate
porous
fluid
section
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PCT/CA2020/050789
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French (fr)
Inventor
Ian Flint
Raymond WILLIAMSON
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2599218 Ontario Inc
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2599218 Ontario Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority to MX2021014041A priority Critical patent/MX2021014041A/en
Priority to JP2021564265A priority patent/JP7572969B2/en
Priority to CA3140950A priority patent/CA3140950C/en
Priority to CN202080038775.1A priority patent/CN113924268B/en
Priority to SM20250359T priority patent/SMT202500359T1/en
Priority to ES20822812T priority patent/ES3043062T3/en
Priority to IL286541A priority patent/IL286541B2/en
Priority to US17/613,135 priority patent/US12042768B2/en
Priority to HRP20251231TT priority patent/HRP20251231T1/en
Application filed by 2599218 Ontario Inc filed Critical 2599218 Ontario Inc
Priority to SG11202110488PA priority patent/SG11202110488PA/en
Priority to KR1020217037389A priority patent/KR20220020255A/en
Priority to EP20822812.2A priority patent/EP3983337B1/en
Priority to AU2020293387A priority patent/AU2020293387B2/en
Publication of WO2020248048A1 publication Critical patent/WO2020248048A1/en
Priority to MX2025000723A priority patent/MX2025000723A/en
Anticipated expiration legal-status Critical
Priority to US18/678,256 priority patent/US20240316505A1/en
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0041—Inorganic membrane manufacture by agglomeration of particles in the dry state
    • B01D67/00416—Inorganic membrane manufacture by agglomeration of particles in the dry state by deposition by filtration through a support or base layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
    • B01D67/0039—Inorganic membrane manufacture
    • B01D67/0046—Inorganic membrane manufacture by slurry techniques, e.g. die or slip-casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/107—Organic support material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/107—Organic support material
    • B01D69/1071—Woven, non-woven or net mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
    • B01J20/28035—Membrane, sheet, cloth, pad, lamellar or mat with more than one layer, e.g. laminates, separated sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
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    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
    • B01J20/28038—Membranes or mats made from fibers or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J20/28095—Shape or type of pores, voids, channels, ducts
    • B01J20/28097—Shape or type of pores, voids, channels, ducts being coated, filled or plugged with specific compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
    • B01J20/3231—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the coating or impregnating layer
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C3/00—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material
    • B05C3/02—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material the work being immersed in the liquid or other fluent material
    • B05C3/09—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material the work being immersed in the liquid or other fluent material for treating separate articles
    • B05C3/109—Passing liquids or other fluent materials into or through chambers containing stationary articles
    • C—CHEMISTRY; METALLURGY
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    • B01D2323/50—Control of the membrane preparation process

Definitions

  • This document relates to graphene membranes. More specifically, this document relates to apparatuses and methods for fabricating graphene membranes.
  • a membrane includes a cross-linked graphene platelet polymer that includes a plurality of cross-linked graphene platelets.
  • the cross-linked graphene platelets include a graphene portion and a cross-linking portion.
  • the cross-linking portion contains a 4 to 10 atom link.
  • the cross-linked graphene platelet polymer is produced by reaction of an epoxide functionalized graphene platelet and a (meth)acrylate or (meth)acrylamide functionalized cross-linker.
  • an apparatus for fabricating a graphene membrane includes a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid.
  • a second section is positionable adjacent the first section.
  • the second section includes a second fluid chamber, and a porous support housed in the second fluid chamber for supporting a porous substrate.
  • the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate.
  • the apparatus further includes a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate.
  • the porous support includes a first layer having pores of a first size, a second layer having pores of a second size larger than the first size, and a third layer having pores of a third size larger than the second size.
  • the first layer can include a sheet of at least one of cellulose, a fabric, and a polymer.
  • the second layer can include a first sub-layer of a sintered polymer or a porous metal, and a second sub-layer of a sintered polymer or a porous metal.
  • the pressurizer is configured to pressurize the first fluid chamber.
  • the pressurizer can include a hydraulic cylinder, a compressed air cylinder, or a high-pressure water pump.
  • the pressurizer includes a vacuum apparatus for creating a vacuum in the second fluid chamber.
  • the apparatus further includes an ultrasonic transducer in the first fluid chamber.
  • the apparatus further includes a substrate support frame having a first piece and a second piece.
  • the porous substrate can be securable between the first piece and the second piece.
  • the substrate support frame can be maneuverable to position the porous substrate on the porous support.
  • the apparatus further includes at least one sensor for sensing a parameter of the suspension, and/or the fluid, and/or the graphene platelets.
  • a method for fabricating a graphene membrane includes a) positioning a porous substrate across a porous support.
  • the porous substrate has a first surface and a second surface, and the porous substrate is positioned so that the first surface faces away from the porous support and the second surface faces towards the porous support.
  • the method further includes b) applying a suspension of graphene platelets in a fluid to a first fluid chamber, to contact the first surface of the porous substrate with the suspension; and c) applying a pressure differential across the porous substrate to force the graphene platelets into the pores of the porous substrate and force the fluid through the porous substrate.
  • step c) includes pressurizing the first fluid chamber. In some examples, step c) includes applying a vacuum to the porous support.
  • the method includes sonicating the suspension during step b) and/or step c).
  • the method further includes, prior to step a), mounting the porous substrate in a substrate support frame.
  • Step a) can include maneuvering the substrate support frame to position the porous substrate across the porous support.
  • the method can further include, after step c), removing the substrate support frame and the porous substrate from the porous support.
  • the method further includes, during step c), sensing a parameter of the suspension and/or the fluid.
  • step c) includes passing the fluid through a first layer, a second layer, and a third layer of the porous support.
  • a system for fabricating a graphene membrane includes an apparatus and a control sub-system.
  • the apparatus includes a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid.
  • the apparatus further includes a second section that is positionable adjacent the first section and having a second fluid chamber and a porous support housed in the second fluid chamber for supporting a porous substrate.
  • the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate.
  • the apparatus further includes at least one sensor for sensing a parameter of the suspension and/or the fluid.
  • the apparatus further includes a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate.
  • the control sub-system can receive information from the sensor and can control the apparatus based on the received information
  • Figure 1 is a perspective view of a system for fabricating a graphene membrane
  • Figure 2 is a perspective view of the substrate support frame of the system of Figure 1 ;
  • Figure 3 is a cross-section taken along line 3-3 in Figure 1 ; and [0024] Figure 4 is an enlarged view of the encircled region in Figure 3.
  • FIG. 10 Generally disclosed herein are apparatuses, methods, and systems for fabricating graphene membranes. More specifically, disclosed herein apparatuses, methods, and systems for fabricating graphene membranes, where the graphene membranes include a porous substrate, and graphene platelets lodged in the pores of the porous substrate and/or deposited as a layer on the surface(s) of the porous substrate.
  • Such graphene membranes are disclosed, for example, in international patent application (PCT) publication no. WO 2020/000086A1 (Flint et al.), United States Patent Application No. 16/542,456 (Flint et al.), and United States Patent Application No.
  • Such graphene membranes may be used, for example, in water filtration and purification, or to form conductive surfaces (e.g. for use in batteries).
  • the apparatuses disclosed herein can allow for a suspension of graphene platelets in a fluid to be applied to a porous substrate, and for a pressure differential to be created across the porous substrate, so that the suspension is forced into the pores of the porous substrate.
  • the fluid can pass through the pores, while the graphene platelets are trapped in the pores, to create the membrane (i.e. where the membrane includes the porous substrate and the graphene platelets lodged in the pores of the porous substrate and/or deposited as a layer on the surface(s) of the porous substrate).
  • the term“platelet” refers to a structure that includes one or multiple (e.g. at least two and up to nine) sheets of graphene.
  • platelets include two, or three sheets of graphene.
  • a platelet can be, for example, up to 15 nanometers thick, with a diameter of up to 100 microns.
  • graphene platelet can refer to a platelet of pure graphene (i.e. non-functionalized graphene) and/or a platelet of functionalized graphene.
  • Functionalized graphene can include, for example, hydroxylated graphene (also referred to as graphene oxide), aminated graphene, and/or hydrogenated graphene. Functionalization of the graphene can create pores in the graphene, which can allow for flow of filtrates, and can create a desired spacing between graphene sheets.
  • the interlayer spacing may be approximately 0.34 nm.
  • the interlayer spacing may be approximately 0.83 nm.
  • the term“porous substrate” refers to a sheet-like material having pores extending therethrough, from a first surface thereof to a second surface thereof.
  • the pores can have a diameter of, for example, less than or equal to 0.03 microns. Preferably, the pores are at most 5 times larger in diameter than the diameter of the graphene platelets.
  • the substrate can have a thickness (i.e. between the first surface and the second surface) of, for example, less than 1 mm.
  • the substrate is a polymer, such as but not limited to polytetrafluoroethylene (Teflon®), polysulfone (PsF) (also referred to as polyether sulfone), cellulose, and/or polyester.
  • the substrate is an acid-treated polymer, for example polysulfone treated with sulfuric acid.
  • the substrate is an acid-treated and ion-treated polymer, for example polysulfone may be treated with sulfuric acid and then with a solution of metal ions (e.g. aluminum or calcium ions).
  • the substrate is non-polymeric, such as a woven cotton.
  • the apparatus 100 generally includes a first section 102, a second section 104, a pressurizer 106, and a substrate support frame 108.
  • the first section 102 is an upper section
  • the second section 104 is a lower section; however, in alternative examples, the first 102 and second 104 sections may be otherwise positioned (e.g. as a left-side section and a right-side section).
  • a porous substrate 1 10 (which ultimately becomes part of the graphene membrane) is supported by the substrate support frame 108.
  • the substrate support frame 108 has a first piece 1 12 and a second piece 1 14, between which the porous substrate 1 10 is securable (e.g. using bolts).
  • the substrate support frame 108 can be used to ease handling of the porous substrate 1 10 and to prevent or minimize physical damage to the porous substrate 1 10.
  • the substrate support frame 108 generally holds the porous substrate 1 10 flat (i.e. it can prevent bending, folding, and/or crimping).
  • the substrate support frame 108 can facilitate positioning of the porous substrate 1 10 between the first section 102 and the second section 104, so that the porous substrate 1 10 is sandwiched between the first section 102 and the second section 104, with a first surface 1 16 of the porous substrate 1 10 facing towards the first section 102 and away from the second section 104, and a second surface 1 18 (shown in Figures 3 and 4) of the porous substrate 1 10 facing towards the second section 104 and away from the first section 102.
  • the first section 102 includes an outer wall 120 (also referred to herein as a“first outer wall”) that defines a fluid chamber 122 (also referred to herein as a“first fluid chamber”).
  • the fluid chamber 122 houses a suspension of graphene platelets in a fluid.
  • the first section 102 includes a pair of fluid inlet ports 126 and an air escape port 127.
  • the first section 102 may include another number of fluid inlet ports, such as one fluid inlet port, and the fluid inlet ports may be in another position.
  • the fluid inlet ports 126 may be opened and closed by a valve (not shown).
  • the first section 102 may include another number of air escape ports, such as more than one air escape port, and the air escape port may be in another position.
  • the air escape port 127 may be opened and closed by a valve (not shown).
  • the first section 102 can further include an ultrasonic transducer (not shown) for sonicating the suspension of graphene platelets, which can help to pack the graphene platelets into the pores of the porous substrate 1 10 (as described in further detail below).
  • an ultrasonic transducer (not shown) for sonicating the suspension of graphene platelets, which can help to pack the graphene platelets into the pores of the porous substrate 1 10 (as described in further detail below).
  • the second section 104 includes an outer wall 128 (also referred to herein as a“second outer wall”) that defines a fluid chamber (also referred to herein as a“second fluid chamber”).
  • the second fluid chamber is not visible in the figures, as it is filled with a porous support 136, described below.
  • the second section 104 is positionable adjacent to the first section 102 so that the first outer wall 120 bears against the second outer wall 128, via the porous substrate 1 10.
  • the second section 104 can further be secured to the first section 102, for example by clamping or bolting the first outer wall 120 to the second outer wall 128.
  • the second fluid chamber has a drain port 134.
  • additional drain ports can be provided (e.g. four drain ports).
  • the second section 104 further includes a porous support 136, which is housed within the second fluid chamber.
  • the porous support 136 supports the porous substrate 1 10 of the graphene membrane, so that when a pressure differential is applied across the porous substrate 1 10, the porous substrate does not tear or rip or break or stretch or otherwise incur damage.
  • the first fluid chamber 122 and the second fluid chamber are in fluid communication via the porous substrate 1 10;
  • the porous support 136 includes several layers, namely a first layer 138, a second layer 140, and a third layer 142.
  • Each layer is porous, with the pore sizes larger than those of the porous substrate 1 10, and becoming larger going from the first layer 138 layer to the third layer 142.
  • the first layer 138 may have pore sizes on the scale of microns
  • the second layer 140 may have pore sizes on the scale of millimeters
  • the third layer 142 may have pore sizes on the scale of inches.
  • the first layer 138 includes a sheet of, for example, cellulose, fabric, and/or various polymers or other materials.
  • the first layer 138 includes more than one sheet of material. The first layer 138 can be in contact with and physically support the porous substrate 1 10 during fabrication of the graphene membrane.
  • the second layer 140 includes two sub-layers: a first sub layer 144 and a second sub-layer 146.
  • the first sub layer 144 and second sub-layer 146 can include, for example, porous materials such as sintered polymers, sintered metals, zeolites, and/or ceramics.
  • the first sub-layer 144 and second sub-layer 146 each include a plexiglass sheet with holes drilled therethrough, with the holes of the first sub-layer 144 being smaller than the holes of the second sub-layer 146.
  • the second layer 140 can contact and physically support the first layer 138, distribute forces caused by the pressure differential (described in more detail below), and direct fluid away from the porous substrate 1 10 (i.e. downwardly, in the example shown).
  • the third layer 142 generally serves to drain the second layer 140, and can be made from various materials having large pores, such as drilled plexiglass.
  • the pressurizer 106 can be any device or apparatus or assembly that in use, can create a pressure differential between the first section 102 and the second section 104 (i.e. between the first fluid chamber 122 and the second fluid chamber, across the porous substrate 1 10), to force the fluid of the suspension through the porous substrate 1 10 and into second fluid chamber and lodge the graphene platelets in the pores of the porous substrate 1 10.
  • the pressurizer 106 is a hydraulic cylinder (shown schematically) that is connected to the first section 102, for pressurizing the fluid chamber 122 of the first section 102, while the second fluid chamber remains at atmospheric pressure (or below atmospheric pressure, e.g. using a vacuum apparatus).
  • the pressurizer can be, for example, a compressed air cylinder, or a mechanical screw, or a high-pressure water pump, or a compressor.
  • the pressurizer can be a vacuum apparatus and can create a vacuum in the second fluid chamber, while the first fluid chamber 122 remains at atmospheric pressure (or above atmospheric pressure). While in the example shown, the hydraulic cylinder moves vertically to pressurize the first fluid chamber 122, in alternative examples, a hydraulic cylinder can move horizontally.
  • the apparatus 100 is part of a system that includes a control sub-system 148.
  • the control sub-system 148 can receive information from the apparatus 100 and/or can control the apparatus 100.
  • the apparatus 100 can include various sensors, such as pressure sensors and/or pH sensors and/or conductivity sensors and/or flow sensors.
  • the control sub-system 148 can receive information from the sensors.
  • Such information can relate, for example, to the pressure differential across the porous substrate 1 10, a concentration of ions in a suspension within the first fluid chamber 122 and/or second fluid chamber, a conductivity of the suspension within the first fluid chamber 122 and/or second fluid chamber, a flow rate across the porous substrate 1 10, and/or a conductivity of the porous substrate 1 10.
  • the control sub-system 148 can control the apparatus 100 based on the received information.
  • the control sub-system 148 can control the pressure differential induced by the pressurizer 106, and/or the entry of fluid into the upper fluid chamber based on the information.
  • a sensor is shown schematically at 150 in Figure 3.
  • the method can include a) positioning the porous substrate 1 10 across the porous support 136 so that the first surface 1 16 faces away from the porous support 136 and the second surface 1 18 faces towards the porous support 136; b) applying a suspension of graphene platelets in a fluid to the fluid chamber 122 of the first section 102, to contact the first surface 1 16 of the porous substrate 1 10 with the suspension; and c) applying a pressure differential across the porous substrate 1 10 to force the graphene platelets into the pores of the porous substrate 1 10 and force the fluid through the porous substrate 1 10.
  • the porous substrate 1 10 may first be mounted in the substrate support frame 108, by securing the porous substrate 1 10 between the first 1 12 and second 1 14 pieces of the substrate support frame 108, as shown in Figure 2.
  • the apparatus 100 may then be assembled as shown in Figure 3, with the substrate support frame positioned 108 outboard of the first fluid chamber 122 and the second fluid chamber, and with the porous substrate 1 10 sandwiched between the first outer wall 120 and the second outer wall 128 and supported by the porous support 136. This can be achieved by opening the apparatus 100 (i.e.
  • a suspension of graphene platelets in a fluid can then be applied to the first fluid chamber 122, so that the suspension is in contact with the first surface 1 16 of the porous substrate 1 10.
  • the suspension can be loaded into the first fluid chamber 122 via one of the fluid inlet ports 126.
  • the suspension includes graphene platelets suspended in a fluid.
  • the fluid can be, for example, a liquid or a gas.
  • the fluid can be or can include a liquid such as water, an alcohol, and/or an organic solvent (e.g. N-Methyl-2- pyrrolidone (NMP)).
  • NMP N-Methyl-2- pyrrolidone
  • the fluid can be or can include a gas such as nitrogen gas, carbon dioxide, noble gases, water vapor, and/or hydrogen gas.
  • various other materials can be suspended in or dissolved in the fluid.
  • the additional materials can be micro- or nano- sized.
  • the suspension can include carbons (e.g. graphite and/or carbon nanotubes), ceramics (such as oxides, carbides, carbonates, and/or phosphates), metals (such as aluminum and/or iron), semiconductors, lipids, and/or polymers.
  • a pressure differential can then be applied across the porous substrate 1 10. As mentioned above, this can be achieved by pressurizing the first fluid chamber 122 and/or applying a vacuum to the second fluid chamber. In the example shown, the pressurizer 106 pressurizes the first fluid chamber 122. Referring to Figure 4, as the pressure differential is applied, the suspension will be forced towards the second section 104. Particularly, as the pressure differential is applied, the fluid 152 (shown schematically) of the suspension will pass through the pores 154 of the porous substrate 1 10, while the graphene platelets 156 will become lodged within the pores 154, leaving behind a graphene membrane (i.e.
  • the suspension can be sonicated, in order to facilitate tight packing of the graphene platelets 156 within the pores 154.
  • the fluid 152 After passing through the pores 154, the fluid 152 will pass into the second section 104, and through the first layer 138, second layer 140, and third layer 142 of the porous support 136. The fluid can then be drained via the drain port 134.
  • control sub-system 148 can be used to receive information from the apparatus 100, and/or to control the apparatus 100.
  • additional suspensions can be applied to the substrate.
  • a first suspension of a first type of graphene platelets e.g. aminated graphene platelets
  • a second suspension of a second type of graphene platelets e.g. oxidized graphene platelets
  • This can result in a graphene membrane that includes several sub-layers of graphene.
  • the apparatus 100 can be disassembled (i.e. by separating the first section 102 and the second section 104), and the substrate support frame 108 and the graphene membrane (which includes the porous support 1 10 with the graphene platelets 156 lodged within the pores 154 of the porous substrate 1 10 and/or deposited as a layer on the porous substrate 1 10) can together be removed from the first section 102 and second section 104.
  • the membrane can then optionally be removed from the substrate support frame 108, or can remain in the substrate support frame 108 for further processing steps.
  • the suspension can be made in the first fluid chamber 122.
  • the fluid and the graphene platelets can be added to the first fluid chamber 122 separately, and then combined in the first fluid chamber 122.
  • the apparatus 100 may alternatively be operated in a semi-batch fashion that approximates or simulates continuous operation.
  • the porous substrate 1 10 and the substrate support frame 108 can move through the first section 102 and second section 104, across the porous support 136.
  • several of the apparatuses 100 may be operated in parallel or in series.
  • each subsequent apparatus 100 can be used to deposit additional graphene platelets 156 onto/into the porous substrate 1 10, or to deposit additional materials onto/into the porous substrate 1 10.
  • the first apparatus in a series can deposit aminated graphene platelets into/onto the porous substrate 1 10, while the second apparatus in the series can deposit oxidized graphene platelets into/onto the porous substrate 1 10.
  • the various parts of the apparatus 100 can be configured for removal, replacement, and cleaning.

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Abstract

An apparatus for fabricating a graphene membrane includes a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid. A second section is positionable adjacent the first section. The second section has a second fluid chamber and a porous support housed in the second fluid chamber for supporting a porous substrate. When the first section is positioned adjacent to the second section and the porous substrate is supported by the porous support, the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate. The apparatus further includes a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate.

Description

APPARATUSES, METHODS, AND SYSTEMS FOR FABRICATING GRAPHENE MEMBRANES
CROSS REFERENCES TO RELATED APPLICTIONS
[0001] This application claims the benefit of and priority to United States Provisional Patent Application No. 62/860,829 filed on June 13, 2019, which is incorporated herein by reference in its entirety.
FIELD
[0002] This document relates to graphene membranes. More specifically, this document relates to apparatuses and methods for fabricating graphene membranes.
BACKGROUND
[0003] US Patent Application Publication No. 2016/0339160 A1 (Bedworth et al.) discloses various systems and methods relating to two-dimensional materials such as graphene. A membrane includes a cross-linked graphene platelet polymer that includes a plurality of cross-linked graphene platelets. The cross-linked graphene platelets include a graphene portion and a cross-linking portion. The cross-linking portion contains a 4 to 10 atom link. The cross-linked graphene platelet polymer is produced by reaction of an epoxide functionalized graphene platelet and a (meth)acrylate or (meth)acrylamide functionalized cross-linker.
SUMMARY
[0004] The following summary is intended to introduce the reader to various aspects of the detailed description, but not to define or delimit any invention.
[0005] Apparatuses for fabricating graphene membranes are disclosed. According to some aspects, an apparatus for fabricating a graphene membrane includes a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid. A second section is positionable adjacent the first section. The second section includes a second fluid chamber, and a porous support housed in the second fluid chamber for supporting a porous substrate. When the first section is positioned adjacent the second section and the porous substrate is supported by the porous support, the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate. The apparatus further includes a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate.
[0006] In some examples, the porous support includes a first layer having pores of a first size, a second layer having pores of a second size larger than the first size, and a third layer having pores of a third size larger than the second size. The first layer can include a sheet of at least one of cellulose, a fabric, and a polymer. The second layer can include a first sub-layer of a sintered polymer or a porous metal, and a second sub-layer of a sintered polymer or a porous metal.
[0007] In some examples, the pressurizer is configured to pressurize the first fluid chamber. The pressurizer can include a hydraulic cylinder, a compressed air cylinder, or a high-pressure water pump.
[0008] In some examples, the pressurizer includes a vacuum apparatus for creating a vacuum in the second fluid chamber.
[0009] In some examples, the apparatus further includes an ultrasonic transducer in the first fluid chamber.
[0010] In some examples, the apparatus further includes a substrate support frame having a first piece and a second piece. The porous substrate can be securable between the first piece and the second piece. The substrate support frame can be maneuverable to position the porous substrate on the porous support.
[0011] In some examples, when the first section is positioned adjacent the second section and the porous substrate is supported by the porous support, the substrate support frame is outboard of the first fluid chamber and the second fluid chamber. [0012] In some examples, the apparatus further includes at least one sensor for sensing a parameter of the suspension, and/or the fluid, and/or the graphene platelets.
[0013] Methods for fabricating graphene membranes are also disclosed. According to some aspects, a method for fabricating a graphene membrane includes a) positioning a porous substrate across a porous support. The porous substrate has a first surface and a second surface, and the porous substrate is positioned so that the first surface faces away from the porous support and the second surface faces towards the porous support. The method further includes b) applying a suspension of graphene platelets in a fluid to a first fluid chamber, to contact the first surface of the porous substrate with the suspension; and c) applying a pressure differential across the porous substrate to force the graphene platelets into the pores of the porous substrate and force the fluid through the porous substrate.
[0014] In some examples, step c) includes pressurizing the first fluid chamber. In some examples, step c) includes applying a vacuum to the porous support.
[0015] In some examples, the method includes sonicating the suspension during step b) and/or step c).
[0016] In some examples, the method further includes, prior to step a), mounting the porous substrate in a substrate support frame. Step a) can include maneuvering the substrate support frame to position the porous substrate across the porous support. The method can further include, after step c), removing the substrate support frame and the porous substrate from the porous support.
[0017] In some examples, the method further includes, during step c), sensing a parameter of the suspension and/or the fluid.
[0018] In some examples, step c) includes passing the fluid through a first layer, a second layer, and a third layer of the porous support.
[0019] Systems for fabricating graphene membranes are also disclosed. According to some aspects, a system for fabricating a graphene membrane includes an apparatus and a control sub-system. The apparatus includes a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid. The apparatus further includes a second section that is positionable adjacent the first section and having a second fluid chamber and a porous support housed in the second fluid chamber for supporting a porous substrate. When the first section is positioned adjacent the second section and the porous substrate is supported by the porous support, the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate. The apparatus further includes at least one sensor for sensing a parameter of the suspension and/or the fluid. The apparatus further includes a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate. The control sub-system can receive information from the sensor and can control the apparatus based on the received information
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. In the drawings:
[0021] Figure 1 is a perspective view of a system for fabricating a graphene membrane;
[0022] Figure 2 is a perspective view of the substrate support frame of the system of Figure 1 ;
[0023] Figure 3 is a cross-section taken along line 3-3 in Figure 1 ; and [0024] Figure 4 is an enlarged view of the encircled region in Figure 3.
DETAILED DESCRIPTION
[0025]Various apparatuses or processes or compositions will be described below to provide an example of an embodiment of the claimed subject matter. No embodiment described below limits any claim and any claim may cover processes or apparatuses or compositions that differ from those described below. The claims are not limited to apparatuses or processes or compositions having all of the features of any one apparatus or process or composition described below or to features common to multiple or all of the apparatuses or processes or compositions described below. It is possible that an apparatus or process or composition described below is not an embodiment of any exclusive right granted by issuance of this patent application. Any subject matter described below and for which an exclusive right is not granted by issuance of this patent application may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such subject matter by its disclosure in this document.
[0026] Generally disclosed herein are apparatuses, methods, and systems for fabricating graphene membranes. More specifically, disclosed herein apparatuses, methods, and systems for fabricating graphene membranes, where the graphene membranes include a porous substrate, and graphene platelets lodged in the pores of the porous substrate and/or deposited as a layer on the surface(s) of the porous substrate. Such graphene membranes are disclosed, for example, in international patent application (PCT) publication no. WO 2020/000086A1 (Flint et al.), United States Patent Application No. 16/542,456 (Flint et al.), and United States Patent Application No. 16/810,918 (Oguntuase), each of which is incorporated herein by reference in its entirety. Such graphene membranes may be used, for example, in water filtration and purification, or to form conductive surfaces (e.g. for use in batteries).
[0027] In general, the apparatuses disclosed herein can allow for a suspension of graphene platelets in a fluid to be applied to a porous substrate, and for a pressure differential to be created across the porous substrate, so that the suspension is forced into the pores of the porous substrate. The fluid can pass through the pores, while the graphene platelets are trapped in the pores, to create the membrane (i.e. where the membrane includes the porous substrate and the graphene platelets lodged in the pores of the porous substrate and/or deposited as a layer on the surface(s) of the porous substrate). [0028] As used herein, the term“platelet” refers to a structure that includes one or multiple (e.g. at least two and up to nine) sheets of graphene. Preferably, platelets include two, or three sheets of graphene. A platelet can be, for example, up to 15 nanometers thick, with a diameter of up to 100 microns. As used herein, the term‘graphene platelet’ can refer to a platelet of pure graphene (i.e. non-functionalized graphene) and/or a platelet of functionalized graphene. Functionalized graphene can include, for example, hydroxylated graphene (also referred to as graphene oxide), aminated graphene, and/or hydrogenated graphene. Functionalization of the graphene can create pores in the graphene, which can allow for flow of filtrates, and can create a desired spacing between graphene sheets. For example, in platelets of non-functionalized graphene, the interlayer spacing may be approximately 0.34 nm. In platelets of functionalized graphene, e.g. graphene that is functionalized as hydroxylated graphene (also known as graphene oxide), the interlayer spacing may be approximately 0.83 nm.
[0029]As used herein, the term“porous substrate” refers to a sheet-like material having pores extending therethrough, from a first surface thereof to a second surface thereof. The pores can have a diameter of, for example, less than or equal to 0.03 microns. Preferably, the pores are at most 5 times larger in diameter than the diameter of the graphene platelets. The substrate can have a thickness (i.e. between the first surface and the second surface) of, for example, less than 1 mm. In some examples the substrate is a polymer, such as but not limited to polytetrafluoroethylene (Teflon®), polysulfone (PsF) (also referred to as polyether sulfone), cellulose, and/or polyester. In some examples, the substrate is an acid-treated polymer, for example polysulfone treated with sulfuric acid. In some examples, the substrate is an acid-treated and ion-treated polymer, for example polysulfone may be treated with sulfuric acid and then with a solution of metal ions (e.g. aluminum or calcium ions). In some examples, the substrate is non-polymeric, such as a woven cotton.
[0030] A first example of an apparatus for fabricating a graphene membrane will now be described. Referring to Figure 1 , the apparatus 100 generally includes a first section 102, a second section 104, a pressurizer 106, and a substrate support frame 108. In the example shown, the first section 102 is an upper section, and the second section 104 is a lower section; however, in alternative examples, the first 102 and second 104 sections may be otherwise positioned (e.g. as a left-side section and a right-side section).
[0031] Referring also to Figure 2, in use, a porous substrate 1 10 (which ultimately becomes part of the graphene membrane) is supported by the substrate support frame 108. The substrate support frame 108 has a first piece 1 12 and a second piece 1 14, between which the porous substrate 1 10 is securable (e.g. using bolts). The substrate support frame 108 can be used to ease handling of the porous substrate 1 10 and to prevent or minimize physical damage to the porous substrate 1 10. The substrate support frame 108 generally holds the porous substrate 1 10 flat (i.e. it can prevent bending, folding, and/or crimping).
[0032] Referring back to Figure 1 , in use, the substrate support frame 108 can facilitate positioning of the porous substrate 1 10 between the first section 102 and the second section 104, so that the porous substrate 1 10 is sandwiched between the first section 102 and the second section 104, with a first surface 1 16 of the porous substrate 1 10 facing towards the first section 102 and away from the second section 104, and a second surface 1 18 (shown in Figures 3 and 4) of the porous substrate 1 10 facing towards the second section 104 and away from the first section 102.
[0033] Referring now to Figure 3, the first section 102 includes an outer wall 120 (also referred to herein as a“first outer wall”) that defines a fluid chamber 122 (also referred to herein as a“first fluid chamber”). In use, as will be described in further detail below, the fluid chamber 122 houses a suspension of graphene platelets in a fluid.
[0034] In the example shown, the first section 102 includes a pair of fluid inlet ports 126 and an air escape port 127. In alternative examples, the first section 102 may include another number of fluid inlet ports, such as one fluid inlet port, and the fluid inlet ports may be in another position. The fluid inlet ports 126 may be opened and closed by a valve (not shown). Furthermore, the first section 102 may include another number of air escape ports, such as more than one air escape port, and the air escape port may be in another position. The air escape port 127 may be opened and closed by a valve (not shown). [0035] The first section 102 can further include an ultrasonic transducer (not shown) for sonicating the suspension of graphene platelets, which can help to pack the graphene platelets into the pores of the porous substrate 1 10 (as described in further detail below).
[0036] Referring still to Figure 3, the second section 104 includes an outer wall 128 (also referred to herein as a“second outer wall”) that defines a fluid chamber (also referred to herein as a“second fluid chamber”). The second fluid chamber is not visible in the figures, as it is filled with a porous support 136, described below. In use, the second section 104 is positionable adjacent to the first section 102 so that the first outer wall 120 bears against the second outer wall 128, via the porous substrate 1 10. The second section 104 can further be secured to the first section 102, for example by clamping or bolting the first outer wall 120 to the second outer wall 128.
[0037] Referring still to Figure 3, the second fluid chamber has a drain port 134. In alternative examples, additional drain ports can be provided (e.g. four drain ports).
[0038] Referring still to Figure 3, the second section 104 further includes a porous support 136, which is housed within the second fluid chamber. In use, during fabrication of a graphene membrane, the porous support 136 supports the porous substrate 1 10 of the graphene membrane, so that when a pressure differential is applied across the porous substrate 1 10, the porous substrate does not tear or rip or break or stretch or otherwise incur damage. Furthermore, in use, when the first section 102 is positioned adjacent the second section 104 and the porous substrate 1 10 is supported by the porous support 136, the first fluid chamber 122 and the second fluid chamber are in fluid communication via the porous substrate 1 10;
[0039] In the example shown, the porous support 136 includes several layers, namely a first layer 138, a second layer 140, and a third layer 142. Each layer is porous, with the pore sizes larger than those of the porous substrate 1 10, and becoming larger going from the first layer 138 layer to the third layer 142. For example, the first layer 138 may have pore sizes on the scale of microns, the second layer 140 may have pore sizes on the scale of millimeters, and the third layer 142 may have pore sizes on the scale of inches. [0040] In some examples, the first layer 138 includes a sheet of, for example, cellulose, fabric, and/or various polymers or other materials. In some examples, the first layer 138 includes more than one sheet of material. The first layer 138 can be in contact with and physically support the porous substrate 1 10 during fabrication of the graphene membrane.
[0041] In the example shown, the second layer 140 includes two sub-layers: a first sub layer 144 and a second sub-layer 146. The first sub layer 144 and second sub-layer 146 can include, for example, porous materials such as sintered polymers, sintered metals, zeolites, and/or ceramics. In some particular examples, the first sub-layer 144 and second sub-layer 146 each include a plexiglass sheet with holes drilled therethrough, with the holes of the first sub-layer 144 being smaller than the holes of the second sub-layer 146. In use, the second layer 140 can contact and physically support the first layer 138, distribute forces caused by the pressure differential (described in more detail below), and direct fluid away from the porous substrate 1 10 (i.e. downwardly, in the example shown).
[0042] In the example shown, the third layer 142 generally serves to drain the second layer 140, and can be made from various materials having large pores, such as drilled plexiglass.
[0043] Referring still to Figure 3, the pressurizer 106 can be any device or apparatus or assembly that in use, can create a pressure differential between the first section 102 and the second section 104 (i.e. between the first fluid chamber 122 and the second fluid chamber, across the porous substrate 1 10), to force the fluid of the suspension through the porous substrate 1 10 and into second fluid chamber and lodge the graphene platelets in the pores of the porous substrate 1 10. In the example shown, the pressurizer 106 is a hydraulic cylinder (shown schematically) that is connected to the first section 102, for pressurizing the fluid chamber 122 of the first section 102, while the second fluid chamber remains at atmospheric pressure (or below atmospheric pressure, e.g. using a vacuum apparatus). In alternative examples the pressurizer can be, for example, a compressed air cylinder, or a mechanical screw, or a high-pressure water pump, or a compressor. Alternatively, the pressurizer can be a vacuum apparatus and can create a vacuum in the second fluid chamber, while the first fluid chamber 122 remains at atmospheric pressure (or above atmospheric pressure). While in the example shown, the hydraulic cylinder moves vertically to pressurize the first fluid chamber 122, in alternative examples, a hydraulic cylinder can move horizontally.
[0044] Referring back to Figure 1 , in the example shown, the apparatus 100 is part of a system that includes a control sub-system 148. The control sub-system 148 can receive information from the apparatus 100 and/or can control the apparatus 100. For example, the apparatus 100 can include various sensors, such as pressure sensors and/or pH sensors and/or conductivity sensors and/or flow sensors. The control sub-system 148 can receive information from the sensors. Such information can relate, for example, to the pressure differential across the porous substrate 1 10, a concentration of ions in a suspension within the first fluid chamber 122 and/or second fluid chamber, a conductivity of the suspension within the first fluid chamber 122 and/or second fluid chamber, a flow rate across the porous substrate 1 10, and/or a conductivity of the porous substrate 1 10. Furthermore, the control sub-system 148 can control the apparatus 100 based on the received information. For example, the control sub-system 148 can control the pressure differential induced by the pressurizer 106, and/or the entry of fluid into the upper fluid chamber based on the information. In the example shown, a sensor is shown schematically at 150 in Figure 3.
[0045] A method of fabricating a graphene membrane will now be described. The method will be described with reference to the apparatus 100; however, the method is not limited to the apparatus 100, and the apparatus 100 is not limited to operation by the method. In general, the method can include a) positioning the porous substrate 1 10 across the porous support 136 so that the first surface 1 16 faces away from the porous support 136 and the second surface 1 18 faces towards the porous support 136; b) applying a suspension of graphene platelets in a fluid to the fluid chamber 122 of the first section 102, to contact the first surface 1 16 of the porous substrate 1 10 with the suspension; and c) applying a pressure differential across the porous substrate 1 10 to force the graphene platelets into the pores of the porous substrate 1 10 and force the fluid through the porous substrate 1 10. [0046] More specifically, in use, the porous substrate 1 10 may first be mounted in the substrate support frame 108, by securing the porous substrate 1 10 between the first 1 12 and second 1 14 pieces of the substrate support frame 108, as shown in Figure 2. The apparatus 100 may then be assembled as shown in Figure 3, with the substrate support frame positioned 108 outboard of the first fluid chamber 122 and the second fluid chamber, and with the porous substrate 1 10 sandwiched between the first outer wall 120 and the second outer wall 128 and supported by the porous support 136. This can be achieved by opening the apparatus 100 (i.e. separating the first section 102 and second section 104), maneuvering the substrate support frame 108 to lay the porous substrate 1 10 on the second section 104, closing the apparatus 100 (positioning the first section 102 adjacent the second section 104), and securing the first section 102 to the second section 104.
[0047] A suspension of graphene platelets in a fluid can then be applied to the first fluid chamber 122, so that the suspension is in contact with the first surface 1 16 of the porous substrate 1 10. For example, the suspension can be loaded into the first fluid chamber 122 via one of the fluid inlet ports 126.
[0048] A mentioned above, the suspension includes graphene platelets suspended in a fluid. The fluid can be, for example, a liquid or a gas. For example, the fluid can be or can include a liquid such as water, an alcohol, and/or an organic solvent (e.g. N-Methyl-2- pyrrolidone (NMP)). Alternatively, the fluid can be or can include a gas such as nitrogen gas, carbon dioxide, noble gases, water vapor, and/or hydrogen gas. In addition to the graphene platelets, various other materials can be suspended in or dissolved in the fluid. The additional materials can be micro- or nano- sized. For example, the suspension can include carbons (e.g. graphite and/or carbon nanotubes), ceramics (such as oxides, carbides, carbonates, and/or phosphates), metals (such as aluminum and/or iron), semiconductors, lipids, and/or polymers.
[0049] A pressure differential can then be applied across the porous substrate 1 10. As mentioned above, this can be achieved by pressurizing the first fluid chamber 122 and/or applying a vacuum to the second fluid chamber. In the example shown, the pressurizer 106 pressurizes the first fluid chamber 122. Referring to Figure 4, as the pressure differential is applied, the suspension will be forced towards the second section 104. Particularly, as the pressure differential is applied, the fluid 152 (shown schematically) of the suspension will pass through the pores 154 of the porous substrate 1 10, while the graphene platelets 156 will become lodged within the pores 154, leaving behind a graphene membrane (i.e. a membrane that includes the porous substrate 1 10 with the graphene platelets 156 lodged within the pores 154 and/or on the first surface 1 16 of the porous substrate). Optionally, while the pressure differential is being applied, the suspension can be sonicated, in order to facilitate tight packing of the graphene platelets 156 within the pores 154.
[0050] After passing through the pores 154, the fluid 152 will pass into the second section 104, and through the first layer 138, second layer 140, and third layer 142 of the porous support 136. The fluid can then be drained via the drain port 134.
[0051] Optionally during pressurization, the control sub-system 148 can be used to receive information from the apparatus 100, and/or to control the apparatus 100.
[0052] Optionally, additional suspensions can be applied to the substrate. For example, a first suspension of a first type of graphene platelets (e.g. aminated graphene platelets) can be applied to the porous substrate 1 10. Then, a second suspension of a second type of graphene platelets (e.g. oxidized graphene platelets) can be applied to the porous substrate. This can result in a graphene membrane that includes several sub-layers of graphene.
[0053] Upon completion of fabrication of the membrane (e.g. when all of the fluid 152 of the suspension has passed from the first fluid chamber 122 into the second fluid chamber), the apparatus 100 can be disassembled (i.e. by separating the first section 102 and the second section 104), and the substrate support frame 108 and the graphene membrane (which includes the porous support 1 10 with the graphene platelets 156 lodged within the pores 154 of the porous substrate 1 10 and/or deposited as a layer on the porous substrate 1 10) can together be removed from the first section 102 and second section 104. The membrane can then optionally be removed from the substrate support frame 108, or can remain in the substrate support frame 108 for further processing steps.
[0054] In some examples, rather than loading the suspension into the first fluid chamber 122, the suspension can be made in the first fluid chamber 122. For example, the fluid and the graphene platelets can be added to the first fluid chamber 122 separately, and then combined in the first fluid chamber 122.
[0055] While the above describes a batch process for fabricating a graphene membrane, the apparatus 100 may alternatively be operated in a semi-batch fashion that approximates or simulates continuous operation. For example, the porous substrate 1 10 and the substrate support frame 108 can move through the first section 102 and second section 104, across the porous support 136. Furthermore, several of the apparatuses 100 may be operated in parallel or in series. When operating in series, each subsequent apparatus 100 can be used to deposit additional graphene platelets 156 onto/into the porous substrate 1 10, or to deposit additional materials onto/into the porous substrate 1 10. For example, the first apparatus in a series can deposit aminated graphene platelets into/onto the porous substrate 1 10, while the second apparatus in the series can deposit oxidized graphene platelets into/onto the porous substrate 1 10.
[0056] Optionally, the various parts of the apparatus 100 can be configured for removal, replacement, and cleaning.
[0057] While the above description provides examples of one or more processes or apparatuses or compositions, it will be appreciated that other processes or apparatuses or compositions may be within the scope of the accompanying claims.
[0058] To the extent any amendments, characterizations, or other assertions previously made (in this or in any related patent applications or patents, including any parent, sibling, or child) with respect to any art, prior or otherwise, could be construed as a disclaimer of any subject matter supported by the present disclosure of this application, Applicant hereby rescinds and retracts such disclaimer. Applicant also respectfully submits that any prior art previously considered in any related patent applications or patents, including any parent, sibling, or child, may need to be re-visited.

Claims

WE CLAIM
1. An apparatus for fabricating a graphene membrane, comprising: a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid; a second section positionable adjacent the first section, the second section having a second fluid chamber and a porous support housed in the second fluid chamber for supporting a porous substrate, wherein when the first section is positioned adjacent the second section and the porous substrate is supported by the porous support, the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate; a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate.
2. The apparatus of claim 1 , wherein the porous support comprises a first layer having pores of a first size, a second layer having pores of a second size larger than the first size, and a third layer having pores of a third size larger than the second size.
3. The apparatus of claim 2, wherein the first layer comprises a sheet of at least one of cellulose, a fabric, and a polymer.
4. The apparatus of claim 2 or claim 3, wherein the second layer comprises a first sub-layer and a second sub-layer.
5. The apparatus of any one of claims 1 to 4, wherein the pressurizer is configured to pressurize the first fluid chamber.
6. The apparatus of claim 5, wherein the pressurizer comprises a hydraulic cylinder, a compressed air cylinder, or a high-pressure water pump.
7. The apparatus of any one of claims 1 to 4, wherein the pressurizer comprises a vacuum apparatus for creating a vacuum in the second fluid chamber.
8. The apparatus of any one of claims 1 to 7, further comprising an ultrasonic transducer in the first fluid chamber.
9. The apparatus of any one of claims 1 to 8, further comprising a substrate support frame, wherein the porous substrate is securable to the substrate support frame, and wherein the substrate support frame is maneuverable to position the porous substrate on the porous support.
10. The apparatus of claim 9, wherein when the first section is positioned adjacent to the second section and the porous substrate is supported by the porous support, the substrate support frame is outboard of the first fluid chamber and the second fluid chamber.
11. The apparatus of any one of claims 1 to 10 further comprising at least one sensor for sensing a parameter of the suspension and/or the fluid and/or the graphene platelets.
12. A method for fabricating a graphene membrane, comprising: a) positioning a porous substrate across a porous support, wherein the porous substrate has a first surface and a second surface, and wherein the porous substrate is positioned so that the first surface faces away from the porous support and the second surface faces towards the porous support; b) applying a suspension of graphene platelets in a fluid to a first fluid chamber, to contact the first surface of the porous substrate with the suspension; c) applying a pressure differential across the porous substrate to force the graphene platelets into the pores of the porous substrate and force the fluid through the porous substrate.
13. The method of claim 12, wherein step c) comprises pressurizing the first fluid chamber.
14. The method of claim 12 or claim 13, wherein step c) comprises applying a vacuum to the porous support.
15. The method of any one of claims 12 to 14, further comprising sonicating the suspension during step b) and/or step c).
16. The method of any one of claims 12 to 15, wherein:
the method further comprises, prior to step a), mounting the porous substrate in a substrate support frame; and
step a) comprises maneuvering the substrate support frame to position the porous substrate across the porous support.
17. The method of claim 16, further comprising, after step c), removing the substrate support frame and the porous substrate from the porous support.
18. The method of any one of claims 12 to 17, further comprising, during step c), sensing a parameter of the suspension and/or the fluid.
19. The method of any one of claims 12 to 19, wherein step c) comprises passing the fluid through a first layer, a second layer, and a third layer of the porous support.
20. A system for fabricating a graphene membrane, comprising: an apparatus comprising (i) a first section having a first fluid chamber for housing a suspension of graphene platelets in a fluid, (ii) a second section positionable adjacent to the first section and having a second fluid chamber and a porous support housed in the second fluid chamber for supporting a porous substrate, wherein when the first section is positioned adjacent to the second section and the porous substrate is supported by the porous support, the first fluid chamber and the second fluid chamber are in fluid communication via the porous substrate, (iii) at least one sensor for sensing a parameter of the suspension and/or the fluid, and (iv) a pressurizer for creating a pressure differential between the first fluid chamber and the second fluid chamber and thereby forcing the fluid through the porous substrate and into the second fluid chamber and lodging the graphene platelets in the pores of the porous substrate; and a control sub-system for receiving information from the sensor and controlling the apparatus based on the received information
PCT/CA2020/050789 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes Ceased WO2020248048A1 (en)

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HRP20251231TT HRP20251231T1 (en) 2019-06-13 2020-06-10 APPARATUS, METHODS AND SYSTEMS FOR MANUFACTURING GRAPHENE MEMBRANES
CA3140950A CA3140950C (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
SG11202110488PA SG11202110488PA (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
SM20250359T SMT202500359T1 (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
ES20822812T ES3043062T3 (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
IL286541A IL286541B2 (en) 2019-06-13 2020-06-10 Devices, methods and systems for producing graphene membranes
US17/613,135 US12042768B2 (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
MX2021014041A MX2021014041A (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes.
CN202080038775.1A CN113924268B (en) 2019-06-13 2020-06-10 Apparatus, method and system for manufacturing graphene film
JP2021564265A JP7572969B2 (en) 2019-06-13 2020-06-10 Apparatus, method and system for fabricating graphene films
KR1020217037389A KR20220020255A (en) 2019-06-13 2020-06-10 Apparatus, method and system for manufacturing graphene membrane
EP20822812.2A EP3983337B1 (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
AU2020293387A AU2020293387B2 (en) 2019-06-13 2020-06-10 Apparatuses, methods, and systems for fabricating graphene membranes
MX2025000723A MX2025000723A (en) 2019-06-13 2021-11-16 Apparatuses, methods, and systems for fabricating graphene membranes
US18/678,256 US20240316505A1 (en) 2019-06-13 2024-05-30 Apparatuses, methods, and systems for fabricating graphene membranes

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