IP Library › Granted Patent US 12,497,517
Granted Patent B1
US 12,497,517 · App. 18/778,707 · Granted Dec 16, 2025

Method of making carbon black

Inventors: Ned J. Hardman (Lincoln, NE); Roscoe W. Taylor (Kingwood, TX)
Assignee: Monolith Materials, Inc.
C09C1/48C01B32/05
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Quick Facts
Patent No.
US 12,497,517
App. No.
18/778,707
Granted
Dec 16, 2025
Kind
B1
Abstract

A method of making tailored carbon black in a plasma process. A method of making tailored carbon black in a plasma process is described, including subjecting the carbon black particles during and/or after formation to surface functionalizing agents in a controlled manner so as to impart a degree and/or density of functionalization onto the carbon black particles so as to adapt the particles to a particular pre-intended application.

Claims (15)

1 . A method of forming a functionalized carbon particle, comprising:

(a) in a thermal plasma process reactor, forming a carbon particle in an atmosphere comprising hydrogen and substantially free of oxygen, wherein the carbon particle is substantially free of surface oxygen functional groups; and

(b) in the thermal plasma process reactor, subjecting the carbon particle to a functionalization agent, thereby functionalizing a surface of the carbon particle to generate a functionalized carbon particle, wherein the subjecting is performed in a controlled manner.

2 . The method of claim 1 , wherein the carbon particle is subjected to the functionalization agent at a temperature of at most about 500° C.

3 . The method of claim 1 , wherein the carbon particle is carbon black.

4 . The method of claim 1 , wherein the functionalization agent is selected from the group consisting of one or more of hydrogen (H 2 ), carbon monoxide (CO), carbon dioxide (CO 2 ), oxygen (O 2 ), water vapor, nitrogen, nitrous oxide (N 2 O), nitrogen dioxide (NO 2 ), ozone, ammonia, amines, methyl amines, hydroxides, peroxides, hydrogen peroxide (H 2 O 2 ), alkali metal super peroxides, acids, nitric acid (HNO 3 ), sulfuric acid (H 2 SO 4 ), persulfates, hypohalites, halites, halates, perhalates, permanganates, potassium permanganate, carbonates, bleach, diazonium salts, diazonium salt of sulfanilic acid, nitrates, nitrate salts, organic nitrates, or any combination thereof.

5 . The method of claim 4 , wherein the functionalization agent is selected from the group consisting of nitric acid, diazonium salts, or any combination thereof.

6 . The method of claim 5 , wherein the functionalization agent is nitric acid and a diazonium salt.

7 . The method of claim 1 , wherein the functionalized carbon particle comprises oxygen containing functional groups.

8 . The method of claim 1 , wherein the functionalized carbon particle comprises carboxylic acid groups.

9 . The method of claim 1 , wherein the functionalized carbon particle comprises phenolic groups.

10 . The method of claim 1 , wherein a surface of the functionalized carbon particle comprises functionalization of at most about 30 micromoles/square meter (μmol/m2).

11 . The method of claim 1 , wherein the functionalization agent comprises one or more oxidizing agents.

12 . The method of claim 1 , wherein the functionalization agent is a gas phase functionalization agent.

13 . The method of claim 1 , wherein the functionalization agent is a liquid phase functionalization agent.

Continuity (2)
Continuation 15229608 · Aug 5, 2016
Provisional Application 62202498 · Aug 7, 2015
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