Apparatus for producing covetic materials from metal-containing precursors

Abstract

The present disclosure provides an apparatus for producing covetic materials that addresses limitations in conventional covetic material production methods. The apparatus utilizes pulsed RF energy to dissociate carbon-containing fluid into carbon species in a first region of a reactor, while a second region receives metal-containing fluid to form metal species. The downstream arrangement of the first and second regions enables controlled mixing of carbon and metal species, followed by cooling at an output port to form covetic materials. The pulsed RF energy configuration and dual-region reactor design provide enhanced control over the dissociation process and material formation compared to existing production methods.

What is claimed is: 
     
         1 . An apparatus for producing covetic materials comprising:
 an energy source configured to generate RF energy;   a first reactor disposed in communication with the RF energy source, the first reactor comprising:   a first region configured to receive a carbon-containing fluid via a first inlet port and the RF energy to dissociate the carbon-containing fluid into carbon species;   a second inlet port configured to receive a metal-containing fluid;   a second region in fluid communication with the first region and the second inlet port, the second region containing a mixture of metal species and carbon species; and   an output port configured to form covetic materials by cooling the mixture.   
     
     
         2 . The apparatus of  claim 1 , wherein the energy source is configured to generate RF energy with a frequency between 100 kHz and 300 GHz. 
     
     
         3 . The apparatus of  claim 1 , wherein the carbon-containing fluid comprises methane, ethane, propane, acetylene, natural gas, methylacetylene-propadiene propane (MAPP), hexane, or combinations thereof. 
     
     
         4 . The apparatus of  claim 1 , wherein the metal-containing fluid comprises at least one of metal carbonyls, metal halides, metal hydrides/nitrides, metal oxides, or organometallic compounds. 
     
     
         5 . The apparatus of  claim 1 , wherein:
 the first region is configured to maintain a first temperature for hydrocarbon dissociation; and   the second region is configured to maintain a second temperature lower than the first temperature for mixture formation.   
     
     
         6 . The apparatus of  claim 1 , further comprising a control system configured to regulate flow rates of the carbon-containing fluid and the metal-containing fluid to achieve a desired ratio of carbon species to metal species in the mixture. 
     
     
         7 . The apparatus of  claim 6 , wherein the control system comprises mass flow controllers and pressure regulators. 
     
     
         8 . The apparatus of  claim 1 , wherein the output port comprises a rapid cooling mechanism configured to quench the mixture and form nanostructured covetic materials. 
     
     
         9 . The apparatus of  claim 8 , wherein the rapid cooling mechanism comprises a heat exchanger or a controlled atmosphere environment. 
     
     
         10 . The apparatus of  claim 1 , wherein:
 the first reactor is constructed from materials selected from quartz, ceramic, and refractory metals; and   the first reactor is configured to withstand high temperatures and RF energy exposure.   
     
     
         11 . The apparatus of  claim 1 , wherein the carbon species comprise carbon radicals, polycyclic aromatics, or graphene sheets. 
     
     
         12 . The apparatus of  claim 1 , wherein the metal species comprise molten metal droplets or semi-molten metal particles. 
     
     
         13 . The apparatus of  claim 1 , wherein:
 the energy source is configured to operate in pulsed mode; and   the pulsed mode enables independent control of plasma density and temperature.   
     
     
         14 . The apparatus of  claim 13 , wherein the pulsed mode comprises variable duty cycles and frequency modulation. 
     
     
         15 . The apparatus of  claim 1 , further comprising a second reactor fluidly connected to the second inlet port, the second reactor configured to dissociate a metal feedstock using thermal or RF energy to produce the metal-containing fluid. 
     
     
         16 . The apparatus of  claim 15 , wherein the second reactor comprises a plasma torch configured to dissociate the metal feedstock using thermal energy. 
     
     
         17 . The apparatus of  claim 1 , wherein:
 the second region comprises mixing enhancement features; and   the mixing enhancement features comprise static mixers, turbulence generators, or residence time optimization elements.   
     
     
         18 . The apparatus of  claim 1 , further comprising in-situ monitoring sensors configured to provide real-time monitoring of temperature, pressure, and composition throughout the first reactor. 
     
     
         19 . The apparatus of  claim 18 , wherein the in-situ monitoring sensors comprise spectroscopic sensors, temperature probes, or flow measurement devices. 
     
     
         20 . The apparatus of  claim 1 , wherein:
 the covetic materials comprise a metal lattice having carbon disposed therein at interstitial sites; and   the carbon is present in an amount ranging from about 1.5 wt % to about 90 wt %; and   the carbon forms non-polar covalent bonds with metal atoms of the metal lattice.   
     
     
         21 . The apparatus of  claim 1 , wherein the metal feedstock comprises trimethyl aluminum (TMA), aluminum chloride, copper chloride, or nickel carbonyl. 
     
     
         22 . The apparatus of  claim 1 , wherein the second reactor comprises a plasma torch configured to dissociate the metal feedstock using thermal energy. 
     
     
         23 . The apparatus of  claim 1 , wherein the carbon species and metal species are configured to form wettable graphene structures where metal particles are disposed on carbon particles. 
     
     
         24 . The apparatus of  claim 1 , wherein the apparatus comprises a dual reactor system with independent energy sources for each reactor. 
     
     
         25 . The apparatus of  claim 1 , wherein the second inlet port is configured to receive a metallic gas that is stable at room temperature. 
     
     
         26 . The apparatus of  claim 1 , wherein the apparatus is configured to produce covetic materials having metal-on-carbon configurations with enhanced wettability characteristics. 
     
     
         27 . The apparatus of  claim 1 , wherein the RF energy source comprises variable frequency capabilities including microwave, radio frequency, DC pulse, or combinations thereof. 
     
     
         28 . The apparatus of  claim 1 , wherein the second reactor comprises a three-chamber configuration for multi-stage metal feedstock processing. 
     
     
         29 . The apparatus of  claim 1 , wherein the apparatus is configured to deposit polymeric compounds onto carbon particles to create battery anode or cathode materials. 
     
     
         30 . The apparatus of  claim 1 , wherein the metal species comprise silicon-containing compounds configured to form silicon-coated carbon materials for battery applications.