Patent
US 10,581,064Process for producing anode layer for lithium ion battery comprising graphene foam
Aruna Zhamu
US
Copyright © 2026 Matter42. All rights reserved.
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG.1 (A) schematic illustrating the notion that expansion of Si particles, upon lithium intercalation, can lead to pulverization of Si particles, interruption …
FIG.2 (A) A flow chart illustrating various prior art processes of producing exfoliated graphite products (flexible graphite foils and expanded graphite flakes), …
FIG.3 (B) schematic of another lithium-ion battery; the anode layer being composed of particles of an anode active material, a conductive additive (not shown) …
FIG.4 A possible mechanism of chemical linking between graphene oxide sheets, which mechanism effectively increases the graphene sheet lateral dimensions.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
FIG.6 (C) Specific capacities of three anode layers: the presently invented GO-derived graphene foam-protected Sn, Sn only (without graphene foam protection), …
FIG.7 Thermal conductivity values of graphene foam samples derived from GO and GF (graphene fluoride) as a function of the specific gravity.
FIG.8 Thermal conductivity values of graphene foam samples derived from GO and pristine graphene as a function of the final (maximum) heat treatment temperature.
FIG.9 (A) Inter-graphene plane spacing in graphene foam walls as measured by X-ray diffraction;
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for producing an anode layer for a lithium ion battery, said process comprising: (a) preparing a graphene dispersion having multiple particles of anode active material and multiple sheets of a starting graphene material dispersed in a liquid medium, wherein said starting graphene material comprises pristine graphene material or non-pristine graphene material, where non-pristine is defined as having a content of non-carbon elements greater than 2% by weight, and where said starting graphene material is selected from the group consisting of graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, and combinations thereof, and wherein said dispersion contains a blowing agent; (b) dispensing said graphene dispersion onto a surface of a supporting substrate to form a wet layer of graphene and anode active material mixture, wherein said dispensing procedure includes subjecting said graphene dispersion to an orientation-inducing stress; (c) partially or completely removing said liquid medium from the wet layer of graphene and anode active material to form a dried layer of mixture material; and (d) heat treating the dried layer of mixture material at a first heat treatment temperature selected from 80 ° C to 3,200 ° C at a desired heating rate sufficient to induce volatile gas molecules from said non-carbon elements or to activate said blowing agent for producing a pore-containing graphene foam anode layer. Currently amended
(Current Amended) The process of claim 1, further including a step of heat-treating the graphene foam anode layer at a second heat treatment temperature higher than said first heat treatment temperature for a length of time sufficient for obtaining [[a]] said anode layer wherein said pores of the pore-containing graphene foam anode layer have walls that contain stacked graphene planes having an inter-plane spacing d 00 2 from 0.3354 nm to 0.36 nm and a content of non-carbon elements less than 2% by weight. Currently amended
The process of claim 1, wherein said blowing agent having a blowing agent-to- graphene weight ratio from 0.01/1.0 to 1.0/1.0. Currently amended
The process of claim 1, wherein said blowing agent is at least one of a physical blowing agent, a chemical blowing agent, a mixture thereof, a dissolution-and- leaching agent, or a mechanically introduced blowing agent. Currently amended
The process of claim 1, which is a roll-to-roll process wherein said steps (b) and (c) include feeding said supporting substrate from a feeder roller to a deposition zone, continuously or intermittently dispensing or depositing said graphene dispersion onto a surface of said supporting substrate to form said wet layer of graphene material thereon, drying said wet layer of graphene material to form the dried layer of graphene material, and collecting said dried layer of graphene material deposited on said supporting substrate on a collector roller. Currently amended
The process of claim 1, wherein said first heat treatment temperature is in a range from 100 ° C to 1,500 0 C. Currently amended
The process of claim 1, wherein said step (d) of heat treating the dried layer of graphene material is conducted under a compressive stress. Currently amended
The process of claim 1, wherein said liquid medium is an oxidizing liquid medium, wherein said graphene dispersion contains [[a]] graphene oxide and the dispersion is prepared by immersing said starting graphene material in a powder or fibrous form in the liquid medium in a reaction vessel at a reaction temperature for a length of time sufficient to obtain said graphene dispersion wherein said graphitic material is selected from natural graphite, artificial graphite, meso[[-]]phase carbon, meso[[-]]phase pitch, meso[[-]]carbon micro[[-]]bead, soft carbon, hard carbon, coke, carbon fiber, carbon nanofiber, carbon nanotube, or a combination thereof and wherein said g raphene oxide has an oxygen content no less than 5% by weight. Currently amended
The process of claim 1, wherein said anode active material is selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (S n), lead (Pb), antimony (Sb), bismuth (Bi), zin c (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (C o), or cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti. Currently amended
The process of claim 1, wherein said anode active material contains at least one of: prelithiated Si, prelithiated Ge, prelithiated S n, prelithiated SnO X, prelithiated SiO X, prelithiated iron oxide, prelithiated V O 2, prelithiated C o 3 O 4, prelithiated Ni 3 O 4, or a combination thereof, wherein 1 < x < 2. Currently amended
The process of claim 1, wherein said anode active material is in at least one of the fo rm s of: nanoparticle, nanowire, nanofiber, nanotube, nanosheet, nanobelt, nanoribbon, or nano-coating having a thickness or diameter less than 100 nm. Currently amended
The process of claim 1, further comprising a lithium-conducting coating deposited onto said anode active material. Original
The process of claim 1, wherein said anode active material has a dimension less than 20 nm. Original
The process of claim 1, further comprising a carbon or graphite material in said dispersion, wherein said carbon or graphite material is in electronic contact with or deposited onto said anode active material. Original
The process of claim 1, wherein said graphene foam anode layer contains pristine graphene and said anode layer has a density from 0.5 to 1.7 g/cm 3 or a pore size from 2 nm to 100 nm. Currently amended
A roll-to-roll process for producing a continuous-length sheet of said anode layer of claim 1, said process comprising: (a) preparing [[a]]said graphene dispersion having a graphene material and an said anode active material dispersed in [[a]]said liquid medium, wherein said dispersion contains [[a]]said blowing agent; (b) continuously or intermittently dispensing and depositing said graphene dispersion onto a surface of [[a]]said supporting substrate to form [[a]]said wet layer of graphene-anode material mixture, wherein said supporting substrate is a continuous thin film supplied from a feeder roller and collected on a collector roller; (c) partially or completely removing said liquid medium from said wet layer of graphene-anode material mixture to form [[a]] said dried layer of mixture material; and (d) heat treating said dried layer of mixture material at [[a]]said first heat treatment temperature in the range from 100 ° C to 3,000 ° C at [[a]]said desired heating rate sufficient to activate said blowing agent for producing said graphene foam anode layer. Currently amended
The process of claim 1, which is in a continuous-length roll sheet form having a thickness no greater than 300 p m and a length of at least 2 meters and is produced by a roll- to-roll process. Original
The process of claim 1, wherein said anode layer has a t least one of: a density from 0.01 to 1.7 g/cm 3, a specific surface area from 50 to 2,000 m 2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, r an electrical conductivity no less than 1,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 1% by weight, and said pores of the pore- containing graphene foam anode layer have walls that have at least one of: an inter-graphene spacing less than 0.35 nm, a thermal conductivity of at least 250 W/mK per unit of specific gravity, r an electrical conductivity no less than 2,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.34 nm, a thermal conductivity of at least 300 W/mK per unit of specific gravity, or an electrical conductivity no less than 3,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content no greater than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an intergraphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.7, a thermal conductivity of at least 350 W/mK per unit of specific gravity, r an electrical conductivity no less than 3,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has pores of the pore-containing graphene foam anode layer that have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.4, a thermal conductivity greater than 400 W/mK per unit of specific gravity, r an electrical conductivity greater than 4,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that include at least one of: stacked graphene planes having an inter-graphene spacing less than 0.337 nm or a mosaic spread value less than 1.0. Currently amended
The process of claim 1, wherein said anode layer has at least one of: a degree of graphitization no less than 80% or a mosaic spread value less than 0.4. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that contain a 3D network of interconnected graphene planes. Currently amended
The process of claim 1, wherein said anode layer contains pores having a pore size in the range from 20 nm to 500 nm. Currently amended
Layer stacks claimed or described, ordered top of device to substrate.
graphene foam anode layer for lithium-ion battery
Materials described outside the worked examples.
graphene foam
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
graphene bromide
graphene iodide
hydrogenated graphene
nitrogenated graphene
chemically functionalized graphene
pristine graphene
anode active material (Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd or alloys)
prelithiated anode active material (prelithiated Si, Ge, Sn, SnOx, SiOx, iron oxide, VO2, Co₃O4, Ni₃O₄)
carbon or graphite material (polymeric carbon, amorphous carbon, CVD carbon, coal tar pitch, petroleum pitch, meso-phase pitch, carbon black, coke, acetylene black, activated carbon, expanded graphite, artificial graphite, natural graphite)
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
inter-plane spacing d002 of pore walls (claim 2) | 0.3354–0.36 | graphene foam |
anode layer density (abstract/claim 21) | 0.01–1.7 | graphene foam |
anode layer specific surface area (abstract/claim 21) | 50–2000 | graphene foam |
thermal conductivity per unit specific gravity (abstract/claim 21) | ≥ 100 | graphene foam |
electrical conductivity per unit specific gravity (abstract/claim 21) | ≥ 1000 | graphene foam |
Temperature | 1500–2500 °C | — |
Temperature | 300–1500 °C | — |
Temperature | 80–300 °C | — |
Duration | 15–120 s | — |
Duration | 900–7200 s | — |
Temperature | 100–1500 °C | — |
Duration | 0.5–96 hours | — |
Temperature | 150–300 °C | — |
Duration | 0.2–1 hour | — |
Temperature | 130–230 °C | — |
Duration | 0.5–5 hours | — |
Duration | 48–72 hours | — |
— | 250–500 W | — |
Thickness | 2–100 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 80–1500 °C | — |
Thickness | 0.6–1.2 nm | — |
Duration | 1–4 hours | — |
Duration | 1–2 hours | — |
Duration | 0.5–2 hours | — |
Temperature | 800–1050 °C | — |
Duration | 5–16 hours | — |
Temperature | 80–350 °C | — |
Duration | 1–8 hours | — |
Temperature | 1500–2850 °C | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 80–500 °C | — |
Duration | 1–5 hours | — |
Duration | 1–10 hours | — |
Thickness | 2–50 nm | — |
Temperature | 200–350 °C | — |
Temperature | 3000–3250 °C | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 300 nm | — |
Temperature | ≤ 2500 °C | — |
Thickness | ≤ 0.344 nm | — |
Pressure | ≤ 1 torr | — |
Thickness | ≤ 0.4 nm | — |
— | ≥ 1 W | — |
Temperature | ≥ 2100 °C | — |
Temperature | ≥ 2500 °C | — |
Temperature | ≥ 80 °C | — |
Temperature | ≥ 300 °C | — |
— | ≥ 350 W | — |
— | ≥ 400 W | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 1 nm | — |
Duration | ≥ 15 minutes | — |
— | ≥ 250 W | — |
Temperature | 80–3200 °C | — |
Thickness | 0.3354–0.36 nm | — |
Temperature | 100–3000 °C | — |
Thickness | 20–500 nm | — |
Temperature | 1500–2100 °C | — |
Temperature | 2100–3200 °C | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 0.35 nm | — |
Thickness | ≤ 0.34 nm | — |
Thickness | ≤ 0.336 nm | — |
Thickness | ≤ 0.337 nm | — |
— | ≥ 300 W | — |
Thickness | 2–200 nm | — |
Thickness | 0.3354–0.4 nm | — |
Thickness | 0.337–0.4 nm | — |
Thickness | 1–200 nm | — |
Thickness | 1–100 nm | — |
Thickness | 1–40 nm | — |
Thickness | 1–30 nm | — |
Thickness | 2–500 nm | — |
Temperature | 1500–3200 °C | — |
Thickness | 2–20 nm | — |
Thickness | ≤ 40 nm | — |
Thickness | ≤ 500 nm | — |
Duration | ≥ 1 hour | — |
— | ≥ 150 W | — |
— | ≥ 200 W | — |
Related documents with shared materials, methods, properties, or citations.
GRAPHENE AEROGELS
PROCESS FOR PRODUCING GRAPHENE FOAM SUPERCAPACITOR ELECTRODE
Graphene Foam-Protected Metal Fluoride and Metal Chloride Cathode Active Materials for Lithium Batteries
PROCESS FOR PRODUCING GRAPHENE FOAM LAMINATE-BASED SEALING MATERIALS
Graphene-Enabled Niobium-Based Composite Metal Oxide as an Anode Active Material for a Lithium-Ion Battery
Integral 3D graphene-carbon hybrid foam
Graphene/Graphite-Based Filament for Thermal Ionization
GRAPHENE DISPLAY DEVICES AND THE DISPLAY DRIVING METHODS THEREOF
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG.1 (A) schematic illustrating the notion that expansion of Si particles, upon lithium intercalation, can lead to pulverization of Si particles, interruption …
FIG.2 (A) A flow chart illustrating various prior art processes of producing exfoliated graphite products (flexible graphite foils and expanded graphite flakes), …
FIG.3 (B) schematic of another lithium-ion battery; the anode layer being composed of particles of an anode active material, a conductive additive (not shown) …
FIG.4 A possible mechanism of chemical linking between graphene oxide sheets, which mechanism effectively increases the graphene sheet lateral dimensions.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
FIG.6 (C) Specific capacities of three anode layers: the presently invented GO-derived graphene foam-protected Sn, Sn only (without graphene foam protection), …
FIG.7 Thermal conductivity values of graphene foam samples derived from GO and GF (graphene fluoride) as a function of the specific gravity.
FIG.8 Thermal conductivity values of graphene foam samples derived from GO and pristine graphene as a function of the final (maximum) heat treatment temperature.
FIG.9 (A) Inter-graphene plane spacing in graphene foam walls as measured by X-ray diffraction;
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for producing an anode layer for a lithium ion battery, said process comprising: (a) preparing a graphene dispersion having multiple particles of anode active material and multiple sheets of a starting graphene material dispersed in a liquid medium, wherein said starting graphene material comprises pristine graphene material or non-pristine graphene material, where non-pristine is defined as having a content of non-carbon elements greater than 2% by weight, and where said starting graphene material is selected from the group consisting of graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, and combinations thereof, and wherein said dispersion contains a blowing agent; (b) dispensing said graphene dispersion onto a surface of a supporting substrate to form a wet layer of graphene and anode active material mixture, wherein said dispensing procedure includes subjecting said graphene dispersion to an orientation-inducing stress; (c) partially or completely removing said liquid medium from the wet layer of graphene and anode active material to form a dried layer of mixture material; and (d) heat treating the dried layer of mixture material at a first heat treatment temperature selected from 80 ° C to 3,200 ° C at a desired heating rate sufficient to induce volatile gas molecules from said non-carbon elements or to activate said blowing agent for producing a pore-containing graphene foam anode layer. Currently amended
(Current Amended) The process of claim 1, further including a step of heat-treating the graphene foam anode layer at a second heat treatment temperature higher than said first heat treatment temperature for a length of time sufficient for obtaining [[a]] said anode layer wherein said pores of the pore-containing graphene foam anode layer have walls that contain stacked graphene planes having an inter-plane spacing d 00 2 from 0.3354 nm to 0.36 nm and a content of non-carbon elements less than 2% by weight. Currently amended
The process of claim 1, wherein said blowing agent having a blowing agent-to- graphene weight ratio from 0.01/1.0 to 1.0/1.0. Currently amended
The process of claim 1, wherein said blowing agent is at least one of a physical blowing agent, a chemical blowing agent, a mixture thereof, a dissolution-and- leaching agent, or a mechanically introduced blowing agent. Currently amended
The process of claim 1, which is a roll-to-roll process wherein said steps (b) and (c) include feeding said supporting substrate from a feeder roller to a deposition zone, continuously or intermittently dispensing or depositing said graphene dispersion onto a surface of said supporting substrate to form said wet layer of graphene material thereon, drying said wet layer of graphene material to form the dried layer of graphene material, and collecting said dried layer of graphene material deposited on said supporting substrate on a collector roller. Currently amended
The process of claim 1, wherein said first heat treatment temperature is in a range from 100 ° C to 1,500 0 C. Currently amended
The process of claim 1, wherein said step (d) of heat treating the dried layer of graphene material is conducted under a compressive stress. Currently amended
The process of claim 1, wherein said liquid medium is an oxidizing liquid medium, wherein said graphene dispersion contains [[a]] graphene oxide and the dispersion is prepared by immersing said starting graphene material in a powder or fibrous form in the liquid medium in a reaction vessel at a reaction temperature for a length of time sufficient to obtain said graphene dispersion wherein said graphitic material is selected from natural graphite, artificial graphite, meso[[-]]phase carbon, meso[[-]]phase pitch, meso[[-]]carbon micro[[-]]bead, soft carbon, hard carbon, coke, carbon fiber, carbon nanofiber, carbon nanotube, or a combination thereof and wherein said g raphene oxide has an oxygen content no less than 5% by weight. Currently amended
The process of claim 1, wherein said anode active material is selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (S n), lead (Pb), antimony (Sb), bismuth (Bi), zin c (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (C o), or cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti. Currently amended
The process of claim 1, wherein said anode active material contains at least one of: prelithiated Si, prelithiated Ge, prelithiated S n, prelithiated SnO X, prelithiated SiO X, prelithiated iron oxide, prelithiated V O 2, prelithiated C o 3 O 4, prelithiated Ni 3 O 4, or a combination thereof, wherein 1 < x < 2. Currently amended
The process of claim 1, wherein said anode active material is in at least one of the fo rm s of: nanoparticle, nanowire, nanofiber, nanotube, nanosheet, nanobelt, nanoribbon, or nano-coating having a thickness or diameter less than 100 nm. Currently amended
The process of claim 1, further comprising a lithium-conducting coating deposited onto said anode active material. Original
The process of claim 1, wherein said anode active material has a dimension less than 20 nm. Original
The process of claim 1, further comprising a carbon or graphite material in said dispersion, wherein said carbon or graphite material is in electronic contact with or deposited onto said anode active material. Original
The process of claim 1, wherein said graphene foam anode layer contains pristine graphene and said anode layer has a density from 0.5 to 1.7 g/cm 3 or a pore size from 2 nm to 100 nm. Currently amended
A roll-to-roll process for producing a continuous-length sheet of said anode layer of claim 1, said process comprising: (a) preparing [[a]]said graphene dispersion having a graphene material and an said anode active material dispersed in [[a]]said liquid medium, wherein said dispersion contains [[a]]said blowing agent; (b) continuously or intermittently dispensing and depositing said graphene dispersion onto a surface of [[a]]said supporting substrate to form [[a]]said wet layer of graphene-anode material mixture, wherein said supporting substrate is a continuous thin film supplied from a feeder roller and collected on a collector roller; (c) partially or completely removing said liquid medium from said wet layer of graphene-anode material mixture to form [[a]] said dried layer of mixture material; and (d) heat treating said dried layer of mixture material at [[a]]said first heat treatment temperature in the range from 100 ° C to 3,000 ° C at [[a]]said desired heating rate sufficient to activate said blowing agent for producing said graphene foam anode layer. Currently amended
The process of claim 1, which is in a continuous-length roll sheet form having a thickness no greater than 300 p m and a length of at least 2 meters and is produced by a roll- to-roll process. Original
The process of claim 1, wherein said anode layer has a t least one of: a density from 0.01 to 1.7 g/cm 3, a specific surface area from 50 to 2,000 m 2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, r an electrical conductivity no less than 1,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 1% by weight, and said pores of the pore- containing graphene foam anode layer have walls that have at least one of: an inter-graphene spacing less than 0.35 nm, a thermal conductivity of at least 250 W/mK per unit of specific gravity, r an electrical conductivity no less than 2,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.34 nm, a thermal conductivity of at least 300 W/mK per unit of specific gravity, or an electrical conductivity no less than 3,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content no greater than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an intergraphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.7, a thermal conductivity of at least 350 W/mK per unit of specific gravity, r an electrical conductivity no less than 3,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has pores of the pore-containing graphene foam anode layer that have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.4, a thermal conductivity greater than 400 W/mK per unit of specific gravity, r an electrical conductivity greater than 4,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that include at least one of: stacked graphene planes having an inter-graphene spacing less than 0.337 nm or a mosaic spread value less than 1.0. Currently amended
The process of claim 1, wherein said anode layer has at least one of: a degree of graphitization no less than 80% or a mosaic spread value less than 0.4. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that contain a 3D network of interconnected graphene planes. Currently amended
The process of claim 1, wherein said anode layer contains pores having a pore size in the range from 20 nm to 500 nm. Currently amended
Layer stacks claimed or described, ordered top of device to substrate.
graphene foam anode layer for lithium-ion battery
Materials described outside the worked examples.
graphene foam
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
graphene bromide
graphene iodide
hydrogenated graphene
nitrogenated graphene
chemically functionalized graphene
pristine graphene
anode active material (Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd or alloys)
prelithiated anode active material (prelithiated Si, Ge, Sn, SnOx, SiOx, iron oxide, VO2, Co₃O4, Ni₃O₄)
carbon or graphite material (polymeric carbon, amorphous carbon, CVD carbon, coal tar pitch, petroleum pitch, meso-phase pitch, carbon black, coke, acetylene black, activated carbon, expanded graphite, artificial graphite, natural graphite)
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
inter-plane spacing d002 of pore walls (claim 2) | 0.3354–0.36 | graphene foam |
anode layer density (abstract/claim 21) | 0.01–1.7 | graphene foam |
anode layer specific surface area (abstract/claim 21) | 50–2000 | graphene foam |
thermal conductivity per unit specific gravity (abstract/claim 21) | ≥ 100 | graphene foam |
electrical conductivity per unit specific gravity (abstract/claim 21) | ≥ 1000 | graphene foam |
Temperature | 1500–2500 °C | — |
Temperature | 300–1500 °C | — |
Temperature | 80–300 °C | — |
Duration | 15–120 s | — |
Duration | 900–7200 s | — |
Temperature | 100–1500 °C | — |
Duration | 0.5–96 hours | — |
Temperature | 150–300 °C | — |
Duration | 0.2–1 hour | — |
Temperature | 130–230 °C | — |
Duration | 0.5–5 hours | — |
Duration | 48–72 hours | — |
— | 250–500 W | — |
Thickness | 2–100 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 80–1500 °C | — |
Thickness | 0.6–1.2 nm | — |
Duration | 1–4 hours | — |
Duration | 1–2 hours | — |
Duration | 0.5–2 hours | — |
Temperature | 800–1050 °C | — |
Duration | 5–16 hours | — |
Temperature | 80–350 °C | — |
Duration | 1–8 hours | — |
Temperature | 1500–2850 °C | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 80–500 °C | — |
Duration | 1–5 hours | — |
Duration | 1–10 hours | — |
Thickness | 2–50 nm | — |
Temperature | 200–350 °C | — |
Temperature | 3000–3250 °C | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 300 nm | — |
Temperature | ≤ 2500 °C | — |
Thickness | ≤ 0.344 nm | — |
Pressure | ≤ 1 torr | — |
Thickness | ≤ 0.4 nm | — |
— | ≥ 1 W | — |
Temperature | ≥ 2100 °C | — |
Temperature | ≥ 2500 °C | — |
Temperature | ≥ 80 °C | — |
Temperature | ≥ 300 °C | — |
— | ≥ 350 W | — |
— | ≥ 400 W | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 1 nm | — |
Duration | ≥ 15 minutes | — |
— | ≥ 250 W | — |
Temperature | 80–3200 °C | — |
Thickness | 0.3354–0.36 nm | — |
Temperature | 100–3000 °C | — |
Thickness | 20–500 nm | — |
Temperature | 1500–2100 °C | — |
Temperature | 2100–3200 °C | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 0.35 nm | — |
Thickness | ≤ 0.34 nm | — |
Thickness | ≤ 0.336 nm | — |
Thickness | ≤ 0.337 nm | — |
— | ≥ 300 W | — |
Thickness | 2–200 nm | — |
Thickness | 0.3354–0.4 nm | — |
Thickness | 0.337–0.4 nm | — |
Thickness | 1–200 nm | — |
Thickness | 1–100 nm | — |
Thickness | 1–40 nm | — |
Thickness | 1–30 nm | — |
Thickness | 2–500 nm | — |
Temperature | 1500–3200 °C | — |
Thickness | 2–20 nm | — |
Thickness | ≤ 40 nm | — |
Thickness | ≤ 500 nm | — |
Duration | ≥ 1 hour | — |
— | ≥ 150 W | — |
— | ≥ 200 W | — |
Related documents with shared materials, methods, properties, or citations.
GRAPHENE AEROGELS
PROCESS FOR PRODUCING GRAPHENE FOAM SUPERCAPACITOR ELECTRODE
Graphene Foam-Protected Metal Fluoride and Metal Chloride Cathode Active Materials for Lithium Batteries
PROCESS FOR PRODUCING GRAPHENE FOAM LAMINATE-BASED SEALING MATERIALS
Graphene-Enabled Niobium-Based Composite Metal Oxide as an Anode Active Material for a Lithium-Ion Battery
Integral 3D graphene-carbon hybrid foam
Graphene/Graphite-Based Filament for Thermal Ionization
GRAPHENE DISPLAY DEVICES AND THE DISPLAY DRIVING METHODS THEREOF
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG.1 (A) schematic illustrating the notion that expansion of Si particles, upon lithium intercalation, can lead to pulverization of Si particles, interruption …
FIG.2 (A) A flow chart illustrating various prior art processes of producing exfoliated graphite products (flexible graphite foils and expanded graphite flakes), …
FIG.3 (B) schematic of another lithium-ion battery; the anode layer being composed of particles of an anode active material, a conductive additive (not shown) …
FIG.4 A possible mechanism of chemical linking between graphene oxide sheets, which mechanism effectively increases the graphene sheet lateral dimensions.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
FIG.6 (C) Specific capacities of three anode layers: the presently invented GO-derived graphene foam-protected Sn, Sn only (without graphene foam protection), …
FIG.7 Thermal conductivity values of graphene foam samples derived from GO and GF (graphene fluoride) as a function of the specific gravity.
FIG.8 Thermal conductivity values of graphene foam samples derived from GO and pristine graphene as a function of the final (maximum) heat treatment temperature.
FIG.9 (A) Inter-graphene plane spacing in graphene foam walls as measured by X-ray diffraction;
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for producing an anode layer for a lithium ion battery, said process comprising: (a) preparing a graphene dispersion having multiple particles of anode active material and multiple sheets of a starting graphene material dispersed in a liquid medium, wherein said starting graphene material comprises pristine graphene material or non-pristine graphene material, where non-pristine is defined as having a content of non-carbon elements greater than 2% by weight, and where said starting graphene material is selected from the group consisting of graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, and combinations thereof, and wherein said dispersion contains a blowing agent; (b) dispensing said graphene dispersion onto a surface of a supporting substrate to form a wet layer of graphene and anode active material mixture, wherein said dispensing procedure includes subjecting said graphene dispersion to an orientation-inducing stress; (c) partially or completely removing said liquid medium from the wet layer of graphene and anode active material to form a dried layer of mixture material; and (d) heat treating the dried layer of mixture material at a first heat treatment temperature selected from 80 ° C to 3,200 ° C at a desired heating rate sufficient to induce volatile gas molecules from said non-carbon elements or to activate said blowing agent for producing a pore-containing graphene foam anode layer. Currently amended
(Current Amended) The process of claim 1, further including a step of heat-treating the graphene foam anode layer at a second heat treatment temperature higher than said first heat treatment temperature for a length of time sufficient for obtaining [[a]] said anode layer wherein said pores of the pore-containing graphene foam anode layer have walls that contain stacked graphene planes having an inter-plane spacing d 00 2 from 0.3354 nm to 0.36 nm and a content of non-carbon elements less than 2% by weight. Currently amended
The process of claim 1, wherein said blowing agent having a blowing agent-to- graphene weight ratio from 0.01/1.0 to 1.0/1.0. Currently amended
The process of claim 1, wherein said blowing agent is at least one of a physical blowing agent, a chemical blowing agent, a mixture thereof, a dissolution-and- leaching agent, or a mechanically introduced blowing agent. Currently amended
The process of claim 1, which is a roll-to-roll process wherein said steps (b) and (c) include feeding said supporting substrate from a feeder roller to a deposition zone, continuously or intermittently dispensing or depositing said graphene dispersion onto a surface of said supporting substrate to form said wet layer of graphene material thereon, drying said wet layer of graphene material to form the dried layer of graphene material, and collecting said dried layer of graphene material deposited on said supporting substrate on a collector roller. Currently amended
The process of claim 1, wherein said first heat treatment temperature is in a range from 100 ° C to 1,500 0 C. Currently amended
The process of claim 1, wherein said step (d) of heat treating the dried layer of graphene material is conducted under a compressive stress. Currently amended
The process of claim 1, wherein said liquid medium is an oxidizing liquid medium, wherein said graphene dispersion contains [[a]] graphene oxide and the dispersion is prepared by immersing said starting graphene material in a powder or fibrous form in the liquid medium in a reaction vessel at a reaction temperature for a length of time sufficient to obtain said graphene dispersion wherein said graphitic material is selected from natural graphite, artificial graphite, meso[[-]]phase carbon, meso[[-]]phase pitch, meso[[-]]carbon micro[[-]]bead, soft carbon, hard carbon, coke, carbon fiber, carbon nanofiber, carbon nanotube, or a combination thereof and wherein said g raphene oxide has an oxygen content no less than 5% by weight. Currently amended
The process of claim 1, wherein said anode active material is selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (S n), lead (Pb), antimony (Sb), bismuth (Bi), zin c (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (C o), or cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti. Currently amended
The process of claim 1, wherein said anode active material contains at least one of: prelithiated Si, prelithiated Ge, prelithiated S n, prelithiated SnO X, prelithiated SiO X, prelithiated iron oxide, prelithiated V O 2, prelithiated C o 3 O 4, prelithiated Ni 3 O 4, or a combination thereof, wherein 1 < x < 2. Currently amended
The process of claim 1, wherein said anode active material is in at least one of the fo rm s of: nanoparticle, nanowire, nanofiber, nanotube, nanosheet, nanobelt, nanoribbon, or nano-coating having a thickness or diameter less than 100 nm. Currently amended
The process of claim 1, further comprising a lithium-conducting coating deposited onto said anode active material. Original
The process of claim 1, wherein said anode active material has a dimension less than 20 nm. Original
The process of claim 1, further comprising a carbon or graphite material in said dispersion, wherein said carbon or graphite material is in electronic contact with or deposited onto said anode active material. Original
The process of claim 1, wherein said graphene foam anode layer contains pristine graphene and said anode layer has a density from 0.5 to 1.7 g/cm 3 or a pore size from 2 nm to 100 nm. Currently amended
A roll-to-roll process for producing a continuous-length sheet of said anode layer of claim 1, said process comprising: (a) preparing [[a]]said graphene dispersion having a graphene material and an said anode active material dispersed in [[a]]said liquid medium, wherein said dispersion contains [[a]]said blowing agent; (b) continuously or intermittently dispensing and depositing said graphene dispersion onto a surface of [[a]]said supporting substrate to form [[a]]said wet layer of graphene-anode material mixture, wherein said supporting substrate is a continuous thin film supplied from a feeder roller and collected on a collector roller; (c) partially or completely removing said liquid medium from said wet layer of graphene-anode material mixture to form [[a]] said dried layer of mixture material; and (d) heat treating said dried layer of mixture material at [[a]]said first heat treatment temperature in the range from 100 ° C to 3,000 ° C at [[a]]said desired heating rate sufficient to activate said blowing agent for producing said graphene foam anode layer. Currently amended
The process of claim 1, which is in a continuous-length roll sheet form having a thickness no greater than 300 p m and a length of at least 2 meters and is produced by a roll- to-roll process. Original
The process of claim 1, wherein said anode layer has a t least one of: a density from 0.01 to 1.7 g/cm 3, a specific surface area from 50 to 2,000 m 2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, r an electrical conductivity no less than 1,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 1% by weight, and said pores of the pore- containing graphene foam anode layer have walls that have at least one of: an inter-graphene spacing less than 0.35 nm, a thermal conductivity of at least 250 W/mK per unit of specific gravity, r an electrical conductivity no less than 2,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.34 nm, a thermal conductivity of at least 300 W/mK per unit of specific gravity, or an electrical conductivity no less than 3,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content no greater than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an intergraphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.7, a thermal conductivity of at least 350 W/mK per unit of specific gravity, r an electrical conductivity no less than 3,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has pores of the pore-containing graphene foam anode layer that have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.4, a thermal conductivity greater than 400 W/mK per unit of specific gravity, r an electrical conductivity greater than 4,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that include at least one of: stacked graphene planes having an inter-graphene spacing less than 0.337 nm or a mosaic spread value less than 1.0. Currently amended
The process of claim 1, wherein said anode layer has at least one of: a degree of graphitization no less than 80% or a mosaic spread value less than 0.4. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that contain a 3D network of interconnected graphene planes. Currently amended
The process of claim 1, wherein said anode layer contains pores having a pore size in the range from 20 nm to 500 nm. Currently amended
Layer stacks claimed or described, ordered top of device to substrate.
graphene foam anode layer for lithium-ion battery
Materials described outside the worked examples.
graphene foam
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
graphene bromide
graphene iodide
hydrogenated graphene
nitrogenated graphene
chemically functionalized graphene
pristine graphene
anode active material (Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd or alloys)
prelithiated anode active material (prelithiated Si, Ge, Sn, SnOx, SiOx, iron oxide, VO2, Co₃O4, Ni₃O₄)
carbon or graphite material (polymeric carbon, amorphous carbon, CVD carbon, coal tar pitch, petroleum pitch, meso-phase pitch, carbon black, coke, acetylene black, activated carbon, expanded graphite, artificial graphite, natural graphite)
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
inter-plane spacing d002 of pore walls (claim 2) | 0.3354–0.36 | graphene foam |
anode layer density (abstract/claim 21) | 0.01–1.7 | graphene foam |
anode layer specific surface area (abstract/claim 21) | 50–2000 | graphene foam |
thermal conductivity per unit specific gravity (abstract/claim 21) | ≥ 100 | graphene foam |
electrical conductivity per unit specific gravity (abstract/claim 21) | ≥ 1000 | graphene foam |
Temperature | 1500–2500 °C | — |
Temperature | 300–1500 °C | — |
Temperature | 80–300 °C | — |
Duration | 15–120 s | — |
Duration | 900–7200 s | — |
Temperature | 100–1500 °C | — |
Duration | 0.5–96 hours | — |
Temperature | 150–300 °C | — |
Duration | 0.2–1 hour | — |
Temperature | 130–230 °C | — |
Duration | 0.5–5 hours | — |
Duration | 48–72 hours | — |
— | 250–500 W | — |
Thickness | 2–100 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 80–1500 °C | — |
Thickness | 0.6–1.2 nm | — |
Duration | 1–4 hours | — |
Duration | 1–2 hours | — |
Duration | 0.5–2 hours | — |
Temperature | 800–1050 °C | — |
Duration | 5–16 hours | — |
Temperature | 80–350 °C | — |
Duration | 1–8 hours | — |
Temperature | 1500–2850 °C | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 80–500 °C | — |
Duration | 1–5 hours | — |
Duration | 1–10 hours | — |
Thickness | 2–50 nm | — |
Temperature | 200–350 °C | — |
Temperature | 3000–3250 °C | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 300 nm | — |
Temperature | ≤ 2500 °C | — |
Thickness | ≤ 0.344 nm | — |
Pressure | ≤ 1 torr | — |
Thickness | ≤ 0.4 nm | — |
— | ≥ 1 W | — |
Temperature | ≥ 2100 °C | — |
Temperature | ≥ 2500 °C | — |
Temperature | ≥ 80 °C | — |
Temperature | ≥ 300 °C | — |
— | ≥ 350 W | — |
— | ≥ 400 W | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 1 nm | — |
Duration | ≥ 15 minutes | — |
— | ≥ 250 W | — |
Temperature | 80–3200 °C | — |
Thickness | 0.3354–0.36 nm | — |
Temperature | 100–3000 °C | — |
Thickness | 20–500 nm | — |
Temperature | 1500–2100 °C | — |
Temperature | 2100–3200 °C | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 0.35 nm | — |
Thickness | ≤ 0.34 nm | — |
Thickness | ≤ 0.336 nm | — |
Thickness | ≤ 0.337 nm | — |
— | ≥ 300 W | — |
Thickness | 2–200 nm | — |
Thickness | 0.3354–0.4 nm | — |
Thickness | 0.337–0.4 nm | — |
Thickness | 1–200 nm | — |
Thickness | 1–100 nm | — |
Thickness | 1–40 nm | — |
Thickness | 1–30 nm | — |
Thickness | 2–500 nm | — |
Temperature | 1500–3200 °C | — |
Thickness | 2–20 nm | — |
Thickness | ≤ 40 nm | — |
Thickness | ≤ 500 nm | — |
Duration | ≥ 1 hour | — |
— | ≥ 150 W | — |
— | ≥ 200 W | — |
Related documents with shared materials, methods, properties, or citations.
GRAPHENE AEROGELS
PROCESS FOR PRODUCING GRAPHENE FOAM SUPERCAPACITOR ELECTRODE
Graphene Foam-Protected Metal Fluoride and Metal Chloride Cathode Active Materials for Lithium Batteries
PROCESS FOR PRODUCING GRAPHENE FOAM LAMINATE-BASED SEALING MATERIALS
Graphene-Enabled Niobium-Based Composite Metal Oxide as an Anode Active Material for a Lithium-Ion Battery
Integral 3D graphene-carbon hybrid foam
Graphene/Graphite-Based Filament for Thermal Ionization
GRAPHENE DISPLAY DEVICES AND THE DISPLAY DRIVING METHODS THEREOF
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG.1 (A) schematic illustrating the notion that expansion of Si particles, upon lithium intercalation, can lead to pulverization of Si particles, interruption …
FIG.2 (A) A flow chart illustrating various prior art processes of producing exfoliated graphite products (flexible graphite foils and expanded graphite flakes), …
FIG.3 (B) schematic of another lithium-ion battery; the anode layer being composed of particles of an anode active material, a conductive additive (not shown) …
FIG.4 A possible mechanism of chemical linking between graphene oxide sheets, which mechanism effectively increases the graphene sheet lateral dimensions.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
FIG.6 (C) Specific capacities of three anode layers: the presently invented GO-derived graphene foam-protected Sn, Sn only (without graphene foam protection), …
FIG.7 Thermal conductivity values of graphene foam samples derived from GO and GF (graphene fluoride) as a function of the specific gravity.
FIG.8 Thermal conductivity values of graphene foam samples derived from GO and pristine graphene as a function of the final (maximum) heat treatment temperature.
FIG.9 (A) Inter-graphene plane spacing in graphene foam walls as measured by X-ray diffraction;
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
A process for producing an anode layer for a lithium ion battery, said process comprising: (a) preparing a graphene dispersion having multiple particles of anode active material and multiple sheets of a starting graphene material dispersed in a liquid medium, wherein said starting graphene material comprises pristine graphene material or non-pristine graphene material, where non-pristine is defined as having a content of non-carbon elements greater than 2% by weight, and where said starting graphene material is selected from the group consisting of graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, chemically functionalized graphene, and combinations thereof, and wherein said dispersion contains a blowing agent; (b) dispensing said graphene dispersion onto a surface of a supporting substrate to form a wet layer of graphene and anode active material mixture, wherein said dispensing procedure includes subjecting said graphene dispersion to an orientation-inducing stress; (c) partially or completely removing said liquid medium from the wet layer of graphene and anode active material to form a dried layer of mixture material; and (d) heat treating the dried layer of mixture material at a first heat treatment temperature selected from 80 ° C to 3,200 ° C at a desired heating rate sufficient to induce volatile gas molecules from said non-carbon elements or to activate said blowing agent for producing a pore-containing graphene foam anode layer. Currently amended
(Current Amended) The process of claim 1, further including a step of heat-treating the graphene foam anode layer at a second heat treatment temperature higher than said first heat treatment temperature for a length of time sufficient for obtaining [[a]] said anode layer wherein said pores of the pore-containing graphene foam anode layer have walls that contain stacked graphene planes having an inter-plane spacing d 00 2 from 0.3354 nm to 0.36 nm and a content of non-carbon elements less than 2% by weight. Currently amended
The process of claim 1, wherein said blowing agent having a blowing agent-to- graphene weight ratio from 0.01/1.0 to 1.0/1.0. Currently amended
The process of claim 1, wherein said blowing agent is at least one of a physical blowing agent, a chemical blowing agent, a mixture thereof, a dissolution-and- leaching agent, or a mechanically introduced blowing agent. Currently amended
The process of claim 1, which is a roll-to-roll process wherein said steps (b) and (c) include feeding said supporting substrate from a feeder roller to a deposition zone, continuously or intermittently dispensing or depositing said graphene dispersion onto a surface of said supporting substrate to form said wet layer of graphene material thereon, drying said wet layer of graphene material to form the dried layer of graphene material, and collecting said dried layer of graphene material deposited on said supporting substrate on a collector roller. Currently amended
The process of claim 1, wherein said first heat treatment temperature is in a range from 100 ° C to 1,500 0 C. Currently amended
The process of claim 1, wherein said step (d) of heat treating the dried layer of graphene material is conducted under a compressive stress. Currently amended
The process of claim 1, wherein said liquid medium is an oxidizing liquid medium, wherein said graphene dispersion contains [[a]] graphene oxide and the dispersion is prepared by immersing said starting graphene material in a powder or fibrous form in the liquid medium in a reaction vessel at a reaction temperature for a length of time sufficient to obtain said graphene dispersion wherein said graphitic material is selected from natural graphite, artificial graphite, meso[[-]]phase carbon, meso[[-]]phase pitch, meso[[-]]carbon micro[[-]]bead, soft carbon, hard carbon, coke, carbon fiber, carbon nanofiber, carbon nanotube, or a combination thereof and wherein said g raphene oxide has an oxygen content no less than 5% by weight. Currently amended
The process of claim 1, wherein said anode active material is selected from the group consisting of: (a) silicon (Si), germanium (Ge), tin (S n), lead (Pb), antimony (Sb), bismuth (Bi), zin c (Zn), aluminum (Al), titanium (Ti), nickel (Ni), cobalt (C o), or cadmium (Cd); (b) alloys or intermetallic compounds of Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti. Currently amended
The process of claim 1, wherein said anode active material contains at least one of: prelithiated Si, prelithiated Ge, prelithiated S n, prelithiated SnO X, prelithiated SiO X, prelithiated iron oxide, prelithiated V O 2, prelithiated C o 3 O 4, prelithiated Ni 3 O 4, or a combination thereof, wherein 1 < x < 2. Currently amended
The process of claim 1, wherein said anode active material is in at least one of the fo rm s of: nanoparticle, nanowire, nanofiber, nanotube, nanosheet, nanobelt, nanoribbon, or nano-coating having a thickness or diameter less than 100 nm. Currently amended
The process of claim 1, further comprising a lithium-conducting coating deposited onto said anode active material. Original
The process of claim 1, wherein said anode active material has a dimension less than 20 nm. Original
The process of claim 1, further comprising a carbon or graphite material in said dispersion, wherein said carbon or graphite material is in electronic contact with or deposited onto said anode active material. Original
The process of claim 1, wherein said graphene foam anode layer contains pristine graphene and said anode layer has a density from 0.5 to 1.7 g/cm 3 or a pore size from 2 nm to 100 nm. Currently amended
A roll-to-roll process for producing a continuous-length sheet of said anode layer of claim 1, said process comprising: (a) preparing [[a]]said graphene dispersion having a graphene material and an said anode active material dispersed in [[a]]said liquid medium, wherein said dispersion contains [[a]]said blowing agent; (b) continuously or intermittently dispensing and depositing said graphene dispersion onto a surface of [[a]]said supporting substrate to form [[a]]said wet layer of graphene-anode material mixture, wherein said supporting substrate is a continuous thin film supplied from a feeder roller and collected on a collector roller; (c) partially or completely removing said liquid medium from said wet layer of graphene-anode material mixture to form [[a]] said dried layer of mixture material; and (d) heat treating said dried layer of mixture material at [[a]]said first heat treatment temperature in the range from 100 ° C to 3,000 ° C at [[a]]said desired heating rate sufficient to activate said blowing agent for producing said graphene foam anode layer. Currently amended
The process of claim 1, which is in a continuous-length roll sheet form having a thickness no greater than 300 p m and a length of at least 2 meters and is produced by a roll- to-roll process. Original
The process of claim 1, wherein said anode layer has a t least one of: a density from 0.01 to 1.7 g/cm 3, a specific surface area from 50 to 2,000 m 2/g, a thermal conductivity of at least 100 W/mK per unit of specific gravity, r an electrical conductivity no less than 1,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 1% by weight, and said pores of the pore- containing graphene foam anode layer have walls that have at least one of: an inter-graphene spacing less than 0.35 nm, a thermal conductivity of at least 250 W/mK per unit of specific gravity, r an electrical conductivity no less than 2,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content less than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.34 nm, a thermal conductivity of at least 300 W/mK per unit of specific gravity, or an electrical conductivity no less than 3,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has an oxygen content or non-carbon content no greater than 0.01% by weight and said pores of the pore-containing graphene foam anode layer have walls that have at least one of: stacked graphene planes having an intergraphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.7, a thermal conductivity of at least 350 W/mK per unit of specific gravity, r an electrical conductivity no less than 3,500 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said anode layer has pores of the pore-containing graphene foam anode layer that have walls that have at least one of: stacked graphene planes having an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.4, a thermal conductivity greater than 400 W/mK per unit of specific gravity, r an electrical conductivity greater than 4,000 S/cm per unit of specific gravity. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that include at least one of: stacked graphene planes having an inter-graphene spacing less than 0.337 nm or a mosaic spread value less than 1.0. Currently amended
The process of claim 1, wherein said anode layer has at least one of: a degree of graphitization no less than 80% or a mosaic spread value less than 0.4. Currently amended
The process of claim 1, wherein said pores of the pore-containing graphene foam anode layer have walls that contain a 3D network of interconnected graphene planes. Currently amended
The process of claim 1, wherein said anode layer contains pores having a pore size in the range from 20 nm to 500 nm. Currently amended
Layer stacks claimed or described, ordered top of device to substrate.
graphene foam anode layer for lithium-ion battery
Materials described outside the worked examples.
graphene foam
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
graphene bromide
graphene iodide
hydrogenated graphene
nitrogenated graphene
chemically functionalized graphene
pristine graphene
anode active material (Si, Ge, Sn, Pb, Sb, Bi, Zn, Al, Ti, Ni, Co, Cd or alloys)
prelithiated anode active material (prelithiated Si, Ge, Sn, SnOx, SiOx, iron oxide, VO2, Co₃O4, Ni₃O₄)
carbon or graphite material (polymeric carbon, amorphous carbon, CVD carbon, coal tar pitch, petroleum pitch, meso-phase pitch, carbon black, coke, acetylene black, activated carbon, expanded graphite, artificial graphite, natural graphite)
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.5 (C) electrical conductivity data for the GO suspension-derived foam produced by the presently invented process and the hydrothermally reduced GO graphene …
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
inter-plane spacing d002 of pore walls (claim 2) | 0.3354–0.36 | graphene foam |
anode layer density (abstract/claim 21) | 0.01–1.7 | graphene foam |
anode layer specific surface area (abstract/claim 21) | 50–2000 | graphene foam |
thermal conductivity per unit specific gravity (abstract/claim 21) | ≥ 100 | graphene foam |
electrical conductivity per unit specific gravity (abstract/claim 21) | ≥ 1000 | graphene foam |
Temperature | 1500–2500 °C | — |
Temperature | 300–1500 °C | — |
Temperature | 80–300 °C | — |
Duration | 15–120 s | — |
Duration | 900–7200 s | — |
Temperature | 100–1500 °C | — |
Duration | 0.5–96 hours | — |
Temperature | 150–300 °C | — |
Duration | 0.2–1 hour | — |
Temperature | 130–230 °C | — |
Duration | 0.5–5 hours | — |
Duration | 48–72 hours | — |
— | 250–500 W | — |
Thickness | 2–100 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 80–1500 °C | — |
Thickness | 0.6–1.2 nm | — |
Duration | 1–4 hours | — |
Duration | 1–2 hours | — |
Duration | 0.5–2 hours | — |
Temperature | 800–1050 °C | — |
Duration | 5–16 hours | — |
Temperature | 80–350 °C | — |
Duration | 1–8 hours | — |
Temperature | 1500–2850 °C | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 80–500 °C | — |
Duration | 1–5 hours | — |
Duration | 1–10 hours | — |
Thickness | 2–50 nm | — |
Temperature | 200–350 °C | — |
Temperature | 3000–3250 °C | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 300 nm | — |
Temperature | ≤ 2500 °C | — |
Thickness | ≤ 0.344 nm | — |
Pressure | ≤ 1 torr | — |
Thickness | ≤ 0.4 nm | — |
— | ≥ 1 W | — |
Temperature | ≥ 2100 °C | — |
Temperature | ≥ 2500 °C | — |
Temperature | ≥ 80 °C | — |
Temperature | ≥ 300 °C | — |
— | ≥ 350 W | — |
— | ≥ 400 W | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 1 nm | — |
Duration | ≥ 15 minutes | — |
— | ≥ 250 W | — |
Temperature | 80–3200 °C | — |
Thickness | 0.3354–0.36 nm | — |
Temperature | 100–3000 °C | — |
Thickness | 20–500 nm | — |
Temperature | 1500–2100 °C | — |
Temperature | 2100–3200 °C | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 0.35 nm | — |
Thickness | ≤ 0.34 nm | — |
Thickness | ≤ 0.336 nm | — |
Thickness | ≤ 0.337 nm | — |
— | ≥ 300 W | — |
Thickness | 2–200 nm | — |
Thickness | 0.3354–0.4 nm | — |
Thickness | 0.337–0.4 nm | — |
Thickness | 1–200 nm | — |
Thickness | 1–100 nm | — |
Thickness | 1–40 nm | — |
Thickness | 1–30 nm | — |
Thickness | 2–500 nm | — |
Temperature | 1500–3200 °C | — |
Thickness | 2–20 nm | — |
Thickness | ≤ 40 nm | — |
Thickness | ≤ 500 nm | — |
Duration | ≥ 1 hour | — |
— | ≥ 150 W | — |
— | ≥ 200 W | — |
Related documents with shared materials, methods, properties, or citations.
GRAPHENE AEROGELS
PROCESS FOR PRODUCING GRAPHENE FOAM SUPERCAPACITOR ELECTRODE
Graphene Foam-Protected Metal Fluoride and Metal Chloride Cathode Active Materials for Lithium Batteries
PROCESS FOR PRODUCING GRAPHENE FOAM LAMINATE-BASED SEALING MATERIALS
Graphene-Enabled Niobium-Based Composite Metal Oxide as an Anode Active Material for a Lithium-Ion Battery
Integral 3D graphene-carbon hybrid foam
Graphene/Graphite-Based Filament for Thermal Ionization
GRAPHENE DISPLAY DEVICES AND THE DISPLAY DRIVING METHODS THEREOF