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Graphene-Carbon Hybrid Foam

A graphene, graphene sheet technology, applied in other chemical processes, ceramic products, applications, etc., can solve problems such as expensive, unrealistic and highly undesirable for industrial-scale production

Active Publication Date: 2018-09-28
NANOTEK INSTR
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0015] (1) The method requires the use of large quantities of several undesirable chemicals such as sulfuric acid, nitric acid, and potassium permanganate or sodium chlorate
[0016] (2) The chemical treatment process requires a long intercalation and oxidation time, typically 5 hours to 5 days
[0019] (5) Both heat- and solution-induced puffing methods require very tedious washing and purification steps
There are several major problems associated with this method: (a) the high pressure requirement makes it an impractical method for industrial scale production
There are several problems associated with this approach: (a) catalytic CVD is inherently a very slow, highly energy-intensive, and expensive process; (b) etchant is typically a highly undesirable chemical and the resulting Ni-containing etching solution is a source of contamination
This method also has several disadvantages: (a) the method requires very tedious chemical treatment of both graphene oxide and PS particles
This method does not involve the use of environmentally unfriendly chemicals

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0143] Example 1: Production of graphene-carbon foams from flake graphite via a solid polymer support based on polypropylene powder

[0144] In the experiment, 1 kg of polypropylene (PP) pellets, 50 g of flake graphite, 50 mesh (average particle size 0.18 mm; Asbury Carbons, Asbury NJ) ) and 250 grams of magnetic steel balls are placed in a high energy ball mill container. The ball mill was operated at 300 rpm for 2 hours. The vessel lid was removed and the stainless steel ball was removed via the magnet. The polymeric support material was found to be coated with a black graphene layer. The support material was placed on a 50 mesh screen and a small amount of raw flake graphite was removed.

[0145] The coated support material samples were then immersed in tetrachlorethylene for 24 h at 80 °C to dissolve the PP and allow the graphene sheets to disperse in the organic solvent. After solvent removal, isolated graphene sheet powders (mostly few-layer graphene) are recovered. ...

example 2

[0148] Example 2: Graphene-carbon hybrid foam using expanded graphite (thickness >100 nm) as graphene source and ABS as polymer solid support particles

[0149] In the experiment, 100 grams of ABS pellets as solid carrier material particles were placed in a 16 oz plastic container along with 5 grams of expanded graphite. The container was placed in an acoustic mixing unit (Resodyn Acoustic mixer company) and processed for 30 minutes. After processing, the support material was found to be coated with a thin layer of carbon. A small sample of the support material was placed in acetone and subjected to ultrasonic energy to accelerate the dissolution of the ABS. The solution was filtered using an appropriate filter and washed four times with additional acetone. Following washing, the filtrate was dried in a vacuum oven set at 60°C for 2 hours. The sample was examined by light microscopy and found to be graphene. The remaining pellets were extruded to produce graphene-polymer s...

example 3

[0150] Example 3: Production of graphene-carbon hybrid foams from mesocarbon microspheres (MCMB as graphene source material) and polyacrylonitrile (PAN) fibers (as solid support particles)

[0151] In one example, 100 grams of PAN fiber segments (2 mm long, as carrier particles), 5 grams of MCMB (China Steel Chemical Co., Taiwan) and 50 grams of zirconia beads were placed in Vibrating ball mill and process for 2 hours. After the process was complete, the vibratory mill was then turned on, and the support material was found to be coated with a black coating of graphene sheets. Zirconia particles of significantly different sizes and colors were manually removed. The graphene-coated PAN fibers were then compacted and melted together to form several composite films. These films were subjected to heat treatment at 250°C for 1 hour (in room air), at 350°C for 2 hours, and at 1,000°C for 2 hours (under an argon atmosphere) to obtain graphene-carbon foam layers. Half of the carboni...

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Abstract

Provided is an integral 3D graphene-carbon hybrid foam composed of multiple pores and pore walls, wherein the pore walls contain single-layer or few-layer graphene sheets chemically bonded by a carbonmaterial having a carbon material-to-graphene weight ratio from 1 / 100 to 1 / 2, wherein the few-layer graphene sheets have 2-10 layers of stacked graphene planes having an inter-plane spacing doo2 from0.3354 nm to 0.40 nm and the graphene sheets contain a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene material having 0.01% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenatedgraphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof. Also provided are a process for producing the hybrid form, products containing the hybridfoam, and its applications.

Description

[0001] Cross References to Related Applications [0002] This application claims priority to US Patent Application Nos. 14 / 998,356 and 14 / 998,357, each filed December 28, 2015, which are hereby incorporated by reference. technical field [0003] The present invention relates generally to the field of carbon / graphite foams, and more particularly to novel forms of porous graphitic materials referred to herein as monolithic 3D graphene-carbon hybrid foams, methods of production thereof, products containing the same, and the manipulation of such product method. Background technique [0004] Carbon is known to have five unique crystal structures, including diamond, fullerene (0-D nanographite material), carbon nanotubes or carbon nanofibers (1-D nanographite material), graphene (2-D nanographite material) and graphite (3-D graphite material). Carbon nanotubes (CNTs) refer to tubular structures grown with single or multiple walls. Carbon nanotubes (CNTs) and carbon nanofibers (...

Claims

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Application Information

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IPC IPC(8): B01J20/20B29C44/04B29C67/24B82Y40/00C04B35/622
CPCB01J20/20B82Y40/00B82Y30/00B01J20/3078B01J20/3204B01J20/324C04B35/522C04B35/524C04B35/6261C04B2235/425C04B2235/5292C04B2235/72C04B2235/96B01J20/28057B01J20/28011B01J20/28045C04B38/0022C04B2111/00793C04B2111/00801C04B38/0054
Inventor 阿茹娜·扎姆张博增
Owner NANOTEK INSTR
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