Patent
US 9,755,225PROCESS FOR SILICON NANOWIRE-GRAPHENE HYBRID MAT
Qing Fang, Aruna Zhamu, Bor Z. Jang
US
Copyright © 2026 Matter42. All rights reserved.
Patent
Atlas literature
Patent
US 9,755,225Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(B) A flow chart showing another preferred route to preparing Si nanowire/graphene hybrid material.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG.4 (B) Another schematic drawing to illustrate the process for producing exfoliated graphite, expanded graphite flakes, and graphene sheets.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.6 Cycling test results of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si nanowires) as the anode active …
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
FIG.8 Cycling test results of three lithium-ion cells: first cell containing original Si particles and exfoliated graphite flakes (no Si nanowires) as the anode …
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 a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a catalyst metal-containing mat comprising a composition selected from the group consisting of: i. graphite flakes and catalyst metal coated or catalyst-metal-precursor coated silicon particles, ii. graphene sheets and catalyst metal coated or catalyst-metal-precursor coated silicon particles, iii. catalyst metal coated or catalyst-metal-precursor coated graphite flakes and silicon particles, or iv. catalyst metal coated or catalyst-metal-precursor coated graphene sheets and silicon particles; and further comprising an optional binder and an optional conductive additive, wherein said silicon particles have a particle diameter from 0.2 p m to pm; (b) optionally drying said catalyst metal-containing mat; (c) optionally exposing said catalyst metal-containing mat to a high temperature environment to convert said optional catalyst-metal-precursor to a catalyst metal; (d) exposing said catalyst metal-containing mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal-catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid porous mat; wherein said silicon nanowires 2. A process for producing a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a porous mat comprising silicon particles, graphite flakes or graphene sheets, an optional binder, and an optional conductive additive wherein said silicon particles have a particle diameter from 0.2 p m to 20 pm; (b) optionally drying said porous mat (c) coating said porous mat with a catalyst metal or catalyst-metal-precursor, creating a catalyst metal-containing porous mat (d) exposing said catalyst metal-containing porous mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal- catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid material porous mat; wherein said silicon nanowires have a diameter less than 100 nm and a length-to-diameter aspect ratio of at least 5. Currently amended
The process of claim 1 or 2, wherein said catalyst-metal-precursor is a salt or organo-metal molecule of a transition metal selected from the group comprising Cu, Ni, Co, Li, Mn, Fe, Ti, Al, Ag, Au, Pt, Pd, Zn, and combinations thereof. Original
The process of claim 1 or 2, wherein said step of l preparing a catalyst metal-containing mat by comprises a procedure of physical vapor deposition, chemical vapor deposition, sputtering, plasma deposition, laser Currently amended
The process of claim 1 or 2, wherein said procedure of exposing said catalyst metal- containing mat to a high temperature environment is conducted in a protective atmosphere of an inert gas, nitrogen gas, hydrogen gas, a mixture thereof, or in a vacuum. Currently amended
The process of claim 1 or 2, further comprising a step of compression. Original
The process of claim 1 or 2, further comprising a process of removing said catalytic metal from said graphene-silicon nanowire hybrid porous mat using chemical etching or electrochemical etching. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, having meso pores therein from 2 nm to 50 nm in size. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, wherein the density is from 0.3 g/cm 3 to 1.2 g/cm 3. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, attached to a copper foil sheet. Original
11. A lithium battery containing the graphene-silicon nanowire hybrid porous mat created by the process of claim 1 or 2 wherein said silicon nanowires are emanated from surfaces of said graphene sheets or graphite flakes. Currently amended
The process of claim 1 or 2, wherein metal catalyst coating is formed by a process comprising: i. dissolving or dispersing a catalytic metal precursor in a liquid to form a precursor solution, ii.bringing said precursor solution in contact with surfaces of said graphene sheets, graphite flakes, or surfaces of said silicon particles, iii.removing said liquid; and iv.chemically or thermally converting said catalytic metal precursor to said catalytic metal coating or nano particles. Currently amended
The process of claim 1, wherein said step (a) of preparing a catalyst metal-containing mat is conducted by liquid solution mixing, homogenizer mixing, high shearing mixing, wet milling, air milling, or ball-milling. 16. The process of claim 1 or 2, further comprising a procedure of incorporating a carbonaceous or graphitic material into said graphene-silicon nanowire hybrid mat as a conductive additive during or after said g raphene-silicon nanowire hybrid mat is made, wherein said carbonaceous or graphitic material is selected from a chemical vapor deposition carbon, physical vapor deposition carbon, amorphous carbon, chemical vapor infiltration carbon, polymeric carbon or carbonized resin, pitch- derived carbon, natural graphite, artificial graphite, meso-phase carbon, meso-phase pitch, meso-carbon micro-bead, soft carbon, hard carbon, coke, carbon fiber, carbon nano-fiber, carbon nano-tube, carbon black, or combinations thereof. Currently amended
A process for producing a graphene-silicon nanowire hybrid material composition, said process comprising: (a) preparing a catalyst metal-coated mixture mass, which includes mixing graphene sheets, having a thickness from 0.34 nm to 100 nm, with micron or sub-micron scaled silicon particles, having a particle diameter from 0.2 p m to 20 p m, to form a mixture and depositing a catalytic metal, in the form of nano particles having a size from 0.5 nm to 100 nm or a coating having a thickness from 1 nm to 100 nm, onto surfaces of said graphene sheets and/or surfaces of said silicon particles, wherein said graphene sheets are selected from the group consisting of graphene chloride, hydrogenated graphene, and combinations thereof and said silicon particles contain pure silicon having at least 99.9% by weight of silicon element or a silicon alloy or mixture having from 70% to 99.9% by weight of silicon therein; and (b) exposing said catalyst metal-coated mixture mass to a high temperature environment, from 300 ° C to 2,000 ° C, to enable a catalytic metal-catalyzed growth of multiple Original
Layer stacks claimed or described, ordered top of device to substrate.
graphene-silicon nanowire hybrid porous mat
lithium battery with graphene-silicon nanowire hybrid anode
Materials described outside the worked examples.
graphene-silicon nanowire hybrid porous mat
graphene sheets
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
silicon nanowire diameter | ≤ 100 nm | Si |
silicon nanowire length-to-diameter aspect ratio | ≥ 5 dimensionless |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 9,755,225Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(B) A flow chart showing another preferred route to preparing Si nanowire/graphene hybrid material.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG.4 (B) Another schematic drawing to illustrate the process for producing exfoliated graphite, expanded graphite flakes, and graphene sheets.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.6 Cycling test results of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si nanowires) as the anode active …
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
FIG.8 Cycling test results of three lithium-ion cells: first cell containing original Si particles and exfoliated graphite flakes (no Si nanowires) as the anode …
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 a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a catalyst metal-containing mat comprising a composition selected from the group consisting of: i. graphite flakes and catalyst metal coated or catalyst-metal-precursor coated silicon particles, ii. graphene sheets and catalyst metal coated or catalyst-metal-precursor coated silicon particles, iii. catalyst metal coated or catalyst-metal-precursor coated graphite flakes and silicon particles, or iv. catalyst metal coated or catalyst-metal-precursor coated graphene sheets and silicon particles; and further comprising an optional binder and an optional conductive additive, wherein said silicon particles have a particle diameter from 0.2 p m to pm; (b) optionally drying said catalyst metal-containing mat; (c) optionally exposing said catalyst metal-containing mat to a high temperature environment to convert said optional catalyst-metal-precursor to a catalyst metal; (d) exposing said catalyst metal-containing mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal-catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid porous mat; wherein said silicon nanowires 2. A process for producing a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a porous mat comprising silicon particles, graphite flakes or graphene sheets, an optional binder, and an optional conductive additive wherein said silicon particles have a particle diameter from 0.2 p m to 20 pm; (b) optionally drying said porous mat (c) coating said porous mat with a catalyst metal or catalyst-metal-precursor, creating a catalyst metal-containing porous mat (d) exposing said catalyst metal-containing porous mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal- catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid material porous mat; wherein said silicon nanowires have a diameter less than 100 nm and a length-to-diameter aspect ratio of at least 5. Currently amended
The process of claim 1 or 2, wherein said catalyst-metal-precursor is a salt or organo-metal molecule of a transition metal selected from the group comprising Cu, Ni, Co, Li, Mn, Fe, Ti, Al, Ag, Au, Pt, Pd, Zn, and combinations thereof. Original
The process of claim 1 or 2, wherein said step of l preparing a catalyst metal-containing mat by comprises a procedure of physical vapor deposition, chemical vapor deposition, sputtering, plasma deposition, laser Currently amended
The process of claim 1 or 2, wherein said procedure of exposing said catalyst metal- containing mat to a high temperature environment is conducted in a protective atmosphere of an inert gas, nitrogen gas, hydrogen gas, a mixture thereof, or in a vacuum. Currently amended
The process of claim 1 or 2, further comprising a step of compression. Original
The process of claim 1 or 2, further comprising a process of removing said catalytic metal from said graphene-silicon nanowire hybrid porous mat using chemical etching or electrochemical etching. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, having meso pores therein from 2 nm to 50 nm in size. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, wherein the density is from 0.3 g/cm 3 to 1.2 g/cm 3. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, attached to a copper foil sheet. Original
11. A lithium battery containing the graphene-silicon nanowire hybrid porous mat created by the process of claim 1 or 2 wherein said silicon nanowires are emanated from surfaces of said graphene sheets or graphite flakes. Currently amended
The process of claim 1 or 2, wherein metal catalyst coating is formed by a process comprising: i. dissolving or dispersing a catalytic metal precursor in a liquid to form a precursor solution, ii.bringing said precursor solution in contact with surfaces of said graphene sheets, graphite flakes, or surfaces of said silicon particles, iii.removing said liquid; and iv.chemically or thermally converting said catalytic metal precursor to said catalytic metal coating or nano particles. Currently amended
The process of claim 1, wherein said step (a) of preparing a catalyst metal-containing mat is conducted by liquid solution mixing, homogenizer mixing, high shearing mixing, wet milling, air milling, or ball-milling. 16. The process of claim 1 or 2, further comprising a procedure of incorporating a carbonaceous or graphitic material into said graphene-silicon nanowire hybrid mat as a conductive additive during or after said g raphene-silicon nanowire hybrid mat is made, wherein said carbonaceous or graphitic material is selected from a chemical vapor deposition carbon, physical vapor deposition carbon, amorphous carbon, chemical vapor infiltration carbon, polymeric carbon or carbonized resin, pitch- derived carbon, natural graphite, artificial graphite, meso-phase carbon, meso-phase pitch, meso-carbon micro-bead, soft carbon, hard carbon, coke, carbon fiber, carbon nano-fiber, carbon nano-tube, carbon black, or combinations thereof. Currently amended
A process for producing a graphene-silicon nanowire hybrid material composition, said process comprising: (a) preparing a catalyst metal-coated mixture mass, which includes mixing graphene sheets, having a thickness from 0.34 nm to 100 nm, with micron or sub-micron scaled silicon particles, having a particle diameter from 0.2 p m to 20 p m, to form a mixture and depositing a catalytic metal, in the form of nano particles having a size from 0.5 nm to 100 nm or a coating having a thickness from 1 nm to 100 nm, onto surfaces of said graphene sheets and/or surfaces of said silicon particles, wherein said graphene sheets are selected from the group consisting of graphene chloride, hydrogenated graphene, and combinations thereof and said silicon particles contain pure silicon having at least 99.9% by weight of silicon element or a silicon alloy or mixture having from 70% to 99.9% by weight of silicon therein; and (b) exposing said catalyst metal-coated mixture mass to a high temperature environment, from 300 ° C to 2,000 ° C, to enable a catalytic metal-catalyzed growth of multiple Original
Layer stacks claimed or described, ordered top of device to substrate.
graphene-silicon nanowire hybrid porous mat
lithium battery with graphene-silicon nanowire hybrid anode
Materials described outside the worked examples.
graphene-silicon nanowire hybrid porous mat
graphene sheets
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
silicon nanowire diameter | ≤ 100 nm | Si |
silicon nanowire length-to-diameter aspect ratio | ≥ 5 dimensionless |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 9,755,225Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(B) A flow chart showing another preferred route to preparing Si nanowire/graphene hybrid material.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG.4 (B) Another schematic drawing to illustrate the process for producing exfoliated graphite, expanded graphite flakes, and graphene sheets.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.6 Cycling test results of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si nanowires) as the anode active …
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
FIG.8 Cycling test results of three lithium-ion cells: first cell containing original Si particles and exfoliated graphite flakes (no Si nanowires) as the anode …
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 a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a catalyst metal-containing mat comprising a composition selected from the group consisting of: i. graphite flakes and catalyst metal coated or catalyst-metal-precursor coated silicon particles, ii. graphene sheets and catalyst metal coated or catalyst-metal-precursor coated silicon particles, iii. catalyst metal coated or catalyst-metal-precursor coated graphite flakes and silicon particles, or iv. catalyst metal coated or catalyst-metal-precursor coated graphene sheets and silicon particles; and further comprising an optional binder and an optional conductive additive, wherein said silicon particles have a particle diameter from 0.2 p m to pm; (b) optionally drying said catalyst metal-containing mat; (c) optionally exposing said catalyst metal-containing mat to a high temperature environment to convert said optional catalyst-metal-precursor to a catalyst metal; (d) exposing said catalyst metal-containing mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal-catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid porous mat; wherein said silicon nanowires 2. A process for producing a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a porous mat comprising silicon particles, graphite flakes or graphene sheets, an optional binder, and an optional conductive additive wherein said silicon particles have a particle diameter from 0.2 p m to 20 pm; (b) optionally drying said porous mat (c) coating said porous mat with a catalyst metal or catalyst-metal-precursor, creating a catalyst metal-containing porous mat (d) exposing said catalyst metal-containing porous mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal- catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid material porous mat; wherein said silicon nanowires have a diameter less than 100 nm and a length-to-diameter aspect ratio of at least 5. Currently amended
The process of claim 1 or 2, wherein said catalyst-metal-precursor is a salt or organo-metal molecule of a transition metal selected from the group comprising Cu, Ni, Co, Li, Mn, Fe, Ti, Al, Ag, Au, Pt, Pd, Zn, and combinations thereof. Original
The process of claim 1 or 2, wherein said step of l preparing a catalyst metal-containing mat by comprises a procedure of physical vapor deposition, chemical vapor deposition, sputtering, plasma deposition, laser Currently amended
The process of claim 1 or 2, wherein said procedure of exposing said catalyst metal- containing mat to a high temperature environment is conducted in a protective atmosphere of an inert gas, nitrogen gas, hydrogen gas, a mixture thereof, or in a vacuum. Currently amended
The process of claim 1 or 2, further comprising a step of compression. Original
The process of claim 1 or 2, further comprising a process of removing said catalytic metal from said graphene-silicon nanowire hybrid porous mat using chemical etching or electrochemical etching. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, having meso pores therein from 2 nm to 50 nm in size. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, wherein the density is from 0.3 g/cm 3 to 1.2 g/cm 3. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, attached to a copper foil sheet. Original
11. A lithium battery containing the graphene-silicon nanowire hybrid porous mat created by the process of claim 1 or 2 wherein said silicon nanowires are emanated from surfaces of said graphene sheets or graphite flakes. Currently amended
The process of claim 1 or 2, wherein metal catalyst coating is formed by a process comprising: i. dissolving or dispersing a catalytic metal precursor in a liquid to form a precursor solution, ii.bringing said precursor solution in contact with surfaces of said graphene sheets, graphite flakes, or surfaces of said silicon particles, iii.removing said liquid; and iv.chemically or thermally converting said catalytic metal precursor to said catalytic metal coating or nano particles. Currently amended
The process of claim 1, wherein said step (a) of preparing a catalyst metal-containing mat is conducted by liquid solution mixing, homogenizer mixing, high shearing mixing, wet milling, air milling, or ball-milling. 16. The process of claim 1 or 2, further comprising a procedure of incorporating a carbonaceous or graphitic material into said graphene-silicon nanowire hybrid mat as a conductive additive during or after said g raphene-silicon nanowire hybrid mat is made, wherein said carbonaceous or graphitic material is selected from a chemical vapor deposition carbon, physical vapor deposition carbon, amorphous carbon, chemical vapor infiltration carbon, polymeric carbon or carbonized resin, pitch- derived carbon, natural graphite, artificial graphite, meso-phase carbon, meso-phase pitch, meso-carbon micro-bead, soft carbon, hard carbon, coke, carbon fiber, carbon nano-fiber, carbon nano-tube, carbon black, or combinations thereof. Currently amended
A process for producing a graphene-silicon nanowire hybrid material composition, said process comprising: (a) preparing a catalyst metal-coated mixture mass, which includes mixing graphene sheets, having a thickness from 0.34 nm to 100 nm, with micron or sub-micron scaled silicon particles, having a particle diameter from 0.2 p m to 20 p m, to form a mixture and depositing a catalytic metal, in the form of nano particles having a size from 0.5 nm to 100 nm or a coating having a thickness from 1 nm to 100 nm, onto surfaces of said graphene sheets and/or surfaces of said silicon particles, wherein said graphene sheets are selected from the group consisting of graphene chloride, hydrogenated graphene, and combinations thereof and said silicon particles contain pure silicon having at least 99.9% by weight of silicon element or a silicon alloy or mixture having from 70% to 99.9% by weight of silicon therein; and (b) exposing said catalyst metal-coated mixture mass to a high temperature environment, from 300 ° C to 2,000 ° C, to enable a catalytic metal-catalyzed growth of multiple Original
Layer stacks claimed or described, ordered top of device to substrate.
graphene-silicon nanowire hybrid porous mat
lithium battery with graphene-silicon nanowire hybrid anode
Materials described outside the worked examples.
graphene-silicon nanowire hybrid porous mat
graphene sheets
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
silicon nanowire diameter | ≤ 100 nm | Si |
silicon nanowire length-to-diameter aspect ratio | ≥ 5 dimensionless |
Related documents with shared materials, methods, properties, or citations.
Patent
Atlas literature
Patent
US 9,755,225Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1(B) A flow chart showing another preferred route to preparing Si nanowire/graphene hybrid material.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG.4 (B) Another schematic drawing to illustrate the process for producing exfoliated graphite, expanded graphite flakes, and graphene sheets.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.6 Cycling test results of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si nanowires) as the anode active …
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
FIG.8 Cycling test results of three lithium-ion cells: first cell containing original Si particles and exfoliated graphite flakes (no Si nanowires) as the anode …
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 a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a catalyst metal-containing mat comprising a composition selected from the group consisting of: i. graphite flakes and catalyst metal coated or catalyst-metal-precursor coated silicon particles, ii. graphene sheets and catalyst metal coated or catalyst-metal-precursor coated silicon particles, iii. catalyst metal coated or catalyst-metal-precursor coated graphite flakes and silicon particles, or iv. catalyst metal coated or catalyst-metal-precursor coated graphene sheets and silicon particles; and further comprising an optional binder and an optional conductive additive, wherein said silicon particles have a particle diameter from 0.2 p m to pm; (b) optionally drying said catalyst metal-containing mat; (c) optionally exposing said catalyst metal-containing mat to a high temperature environment to convert said optional catalyst-metal-precursor to a catalyst metal; (d) exposing said catalyst metal-containing mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal-catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid porous mat; wherein said silicon nanowires 2. A process for producing a graphene-silicon nanowire hybrid porous mat, said process comprising: (a) preparing a porous mat comprising silicon particles, graphite flakes or graphene sheets, an optional binder, and an optional conductive additive wherein said silicon particles have a particle diameter from 0.2 p m to 20 pm; (b) optionally drying said porous mat (c) coating said porous mat with a catalyst metal or catalyst-metal-precursor, creating a catalyst metal-containing porous mat (d) exposing said catalyst metal-containing porous mat to a high temperature environment from 300 ° C to 2,000 ° C to enable a catalytic metal- catalyzed growth of multiple silicon nanowires from said silicon particles as a feed material to form said graphene-silicon nanowire hybrid material porous mat; wherein said silicon nanowires have a diameter less than 100 nm and a length-to-diameter aspect ratio of at least 5. Currently amended
The process of claim 1 or 2, wherein said catalyst-metal-precursor is a salt or organo-metal molecule of a transition metal selected from the group comprising Cu, Ni, Co, Li, Mn, Fe, Ti, Al, Ag, Au, Pt, Pd, Zn, and combinations thereof. Original
The process of claim 1 or 2, wherein said step of l preparing a catalyst metal-containing mat by comprises a procedure of physical vapor deposition, chemical vapor deposition, sputtering, plasma deposition, laser Currently amended
The process of claim 1 or 2, wherein said procedure of exposing said catalyst metal- containing mat to a high temperature environment is conducted in a protective atmosphere of an inert gas, nitrogen gas, hydrogen gas, a mixture thereof, or in a vacuum. Currently amended
The process of claim 1 or 2, further comprising a step of compression. Original
The process of claim 1 or 2, further comprising a process of removing said catalytic metal from said graphene-silicon nanowire hybrid porous mat using chemical etching or electrochemical etching. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, having meso pores therein from 2 nm to 50 nm in size. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, wherein the density is from 0.3 g/cm 3 to 1.2 g/cm 3. Original
The graphene-silicon nanowire hybrid mat of claims 1 or 2, attached to a copper foil sheet. Original
11. A lithium battery containing the graphene-silicon nanowire hybrid porous mat created by the process of claim 1 or 2 wherein said silicon nanowires are emanated from surfaces of said graphene sheets or graphite flakes. Currently amended
The process of claim 1 or 2, wherein metal catalyst coating is formed by a process comprising: i. dissolving or dispersing a catalytic metal precursor in a liquid to form a precursor solution, ii.bringing said precursor solution in contact with surfaces of said graphene sheets, graphite flakes, or surfaces of said silicon particles, iii.removing said liquid; and iv.chemically or thermally converting said catalytic metal precursor to said catalytic metal coating or nano particles. Currently amended
The process of claim 1, wherein said step (a) of preparing a catalyst metal-containing mat is conducted by liquid solution mixing, homogenizer mixing, high shearing mixing, wet milling, air milling, or ball-milling. 16. The process of claim 1 or 2, further comprising a procedure of incorporating a carbonaceous or graphitic material into said graphene-silicon nanowire hybrid mat as a conductive additive during or after said g raphene-silicon nanowire hybrid mat is made, wherein said carbonaceous or graphitic material is selected from a chemical vapor deposition carbon, physical vapor deposition carbon, amorphous carbon, chemical vapor infiltration carbon, polymeric carbon or carbonized resin, pitch- derived carbon, natural graphite, artificial graphite, meso-phase carbon, meso-phase pitch, meso-carbon micro-bead, soft carbon, hard carbon, coke, carbon fiber, carbon nano-fiber, carbon nano-tube, carbon black, or combinations thereof. Currently amended
A process for producing a graphene-silicon nanowire hybrid material composition, said process comprising: (a) preparing a catalyst metal-coated mixture mass, which includes mixing graphene sheets, having a thickness from 0.34 nm to 100 nm, with micron or sub-micron scaled silicon particles, having a particle diameter from 0.2 p m to 20 p m, to form a mixture and depositing a catalytic metal, in the form of nano particles having a size from 0.5 nm to 100 nm or a coating having a thickness from 1 nm to 100 nm, onto surfaces of said graphene sheets and/or surfaces of said silicon particles, wherein said graphene sheets are selected from the group consisting of graphene chloride, hydrogenated graphene, and combinations thereof and said silicon particles contain pure silicon having at least 99.9% by weight of silicon element or a silicon alloy or mixture having from 70% to 99.9% by weight of silicon therein; and (b) exposing said catalyst metal-coated mixture mass to a high temperature environment, from 300 ° C to 2,000 ° C, to enable a catalytic metal-catalyzed growth of multiple Original
Layer stacks claimed or described, ordered top of device to substrate.
graphene-silicon nanowire hybrid porous mat
lithium battery with graphene-silicon nanowire hybrid anode
Materials described outside the worked examples.
graphene-silicon nanowire hybrid porous mat
graphene sheets
Additional fabrication and treatment steps described in the patent.
Measurements and analyses referenced in the patent, with their drawing references.
FIG.2 SEM image of Si nanowires grown from Si micron particles without the presence of graphene sheets.
Performance values and ranges asserted in the specification or claims.
| Property | Value | Material |
|---|---|---|
silicon nanowire diameter | ≤ 100 nm | Si |
silicon nanowire length-to-diameter aspect ratio | ≥ 5 dimensionless |
Related documents with shared materials, methods, properties, or citations.
graphite flakes
silicon particles
Si
catalyst metal/catalyst metal precursor
copper foil
Cu
carbonaceous or graphitic conductive additive
pristine graphene
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
hydrogenated graphene
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
meso pore size in graphene-silicon nanowire hybrid mat | 2–50 nm | graphene-silicon nanowire hybrid porous mat |
density of graphene-silicon nanowire hybrid mat | 0.3–1.2 g/cm3 | graphene-silicon nanowire hybrid porous mat |
Temperature | 300–2000 °C | — |
Temperature | 400–1500 °C | — |
Temperature | 500–1200 °C | — |
Thickness | 1–100 nm | — |
Temperature | 700–1000 °C | — |
Temperature | 1000–2000 °C | — |
Duration | 30–120 s | — |
Duration | 900–7200 s | — |
Thickness | 2–20 nm | — |
Duration | 24–96 hours | — |
Duration | 0.5–96 hours | — |
Duration | 48–72 hours | — |
Thickness | 2–10 nm | — |
Temperature | 450–650 °C | — |
Temperature | 800–1050 °C | — |
Thickness | 0.6–1.1 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 500–1500 °C | — |
Temperature | 350–1500 °C | — |
Temperature | 300–700 °C | — |
Temperature | 700–1200 °C | — |
Duration | 5–16 hours | — |
Temperature | 800–1500 °C | — |
Thickness | 2–100 nm | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 300–800 °C | — |
Duration | 1–5 hours | — |
Thickness | 40–100 nm | — |
Thickness | 60–90 nm | — |
Thickness | 5–20 nm | — |
Thickness | 10–20 nm | — |
Thickness | 50–100 nm | — |
Thickness | 20–50 nm | — |
Thickness | 1–10 nm | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 50 nm | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 10 nm | — |
Thickness | ≤ 7 nm | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 30 nm | — |
Thickness | ≥ 50 nm | — |
Thickness | ≥ 1 nm | — |
Thickness | 0.34–100 nm | — |
Thickness | 0.5–100 nm | — |
Thickness | 5–200 nm | — |
Thickness | 10–100 nm | — |
Thickness | 2–200 nm | — |
graphite flakes
silicon particles
Si
catalyst metal/catalyst metal precursor
copper foil
Cu
carbonaceous or graphitic conductive additive
pristine graphene
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
hydrogenated graphene
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
meso pore size in graphene-silicon nanowire hybrid mat | 2–50 nm | graphene-silicon nanowire hybrid porous mat |
density of graphene-silicon nanowire hybrid mat | 0.3–1.2 g/cm3 | graphene-silicon nanowire hybrid porous mat |
Temperature | 300–2000 °C | — |
Temperature | 400–1500 °C | — |
Temperature | 500–1200 °C | — |
Thickness | 1–100 nm | — |
Temperature | 700–1000 °C | — |
Temperature | 1000–2000 °C | — |
Duration | 30–120 s | — |
Duration | 900–7200 s | — |
Thickness | 2–20 nm | — |
Duration | 24–96 hours | — |
Duration | 0.5–96 hours | — |
Duration | 48–72 hours | — |
Thickness | 2–10 nm | — |
Temperature | 450–650 °C | — |
Temperature | 800–1050 °C | — |
Thickness | 0.6–1.1 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 500–1500 °C | — |
Temperature | 350–1500 °C | — |
Temperature | 300–700 °C | — |
Temperature | 700–1200 °C | — |
Duration | 5–16 hours | — |
Temperature | 800–1500 °C | — |
Thickness | 2–100 nm | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 300–800 °C | — |
Duration | 1–5 hours | — |
Thickness | 40–100 nm | — |
Thickness | 60–90 nm | — |
Thickness | 5–20 nm | — |
Thickness | 10–20 nm | — |
Thickness | 50–100 nm | — |
Thickness | 20–50 nm | — |
Thickness | 1–10 nm | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 50 nm | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 10 nm | — |
Thickness | ≤ 7 nm | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 30 nm | — |
Thickness | ≥ 50 nm | — |
Thickness | ≥ 1 nm | — |
Thickness | 0.34–100 nm | — |
Thickness | 0.5–100 nm | — |
Thickness | 5–200 nm | — |
Thickness | 10–100 nm | — |
Thickness | 2–200 nm | — |
graphite flakes
silicon particles
Si
catalyst metal/catalyst metal precursor
copper foil
Cu
carbonaceous or graphitic conductive additive
pristine graphene
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
hydrogenated graphene
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
meso pore size in graphene-silicon nanowire hybrid mat | 2–50 nm | graphene-silicon nanowire hybrid porous mat |
density of graphene-silicon nanowire hybrid mat | 0.3–1.2 g/cm3 | graphene-silicon nanowire hybrid porous mat |
Temperature | 300–2000 °C | — |
Temperature | 400–1500 °C | — |
Temperature | 500–1200 °C | — |
Thickness | 1–100 nm | — |
Temperature | 700–1000 °C | — |
Temperature | 1000–2000 °C | — |
Duration | 30–120 s | — |
Duration | 900–7200 s | — |
Thickness | 2–20 nm | — |
Duration | 24–96 hours | — |
Duration | 0.5–96 hours | — |
Duration | 48–72 hours | — |
Thickness | 2–10 nm | — |
Temperature | 450–650 °C | — |
Temperature | 800–1050 °C | — |
Thickness | 0.6–1.1 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 500–1500 °C | — |
Temperature | 350–1500 °C | — |
Temperature | 300–700 °C | — |
Temperature | 700–1200 °C | — |
Duration | 5–16 hours | — |
Temperature | 800–1500 °C | — |
Thickness | 2–100 nm | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 300–800 °C | — |
Duration | 1–5 hours | — |
Thickness | 40–100 nm | — |
Thickness | 60–90 nm | — |
Thickness | 5–20 nm | — |
Thickness | 10–20 nm | — |
Thickness | 50–100 nm | — |
Thickness | 20–50 nm | — |
Thickness | 1–10 nm | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 50 nm | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 10 nm | — |
Thickness | ≤ 7 nm | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 30 nm | — |
Thickness | ≥ 50 nm | — |
Thickness | ≥ 1 nm | — |
Thickness | 0.34–100 nm | — |
Thickness | 0.5–100 nm | — |
Thickness | 5–200 nm | — |
Thickness | 10–100 nm | — |
Thickness | 2–200 nm | — |
graphite flakes
silicon particles
Si
catalyst metal/catalyst metal precursor
copper foil
Cu
carbonaceous or graphitic conductive additive
pristine graphene
graphene oxide
reduced graphene oxide
graphene fluoride
graphene chloride
hydrogenated graphene
FIG.3 (A) SEM image of Si nanowires grown from Si micron particles supported by graphene sheets;
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG. 5(A), but taken at a higher magnification; and 10 F IG.5 (C) TEM image of single-layer graphene sheets partially stacked together.
FIG.7 Ragone plots (power density vs. energy density) of three lithium-ion cells: first cell containing original Si particles and graphene sheets (no Si …
meso pore size in graphene-silicon nanowire hybrid mat | 2–50 nm | graphene-silicon nanowire hybrid porous mat |
density of graphene-silicon nanowire hybrid mat | 0.3–1.2 g/cm3 | graphene-silicon nanowire hybrid porous mat |
Temperature | 300–2000 °C | — |
Temperature | 400–1500 °C | — |
Temperature | 500–1200 °C | — |
Thickness | 1–100 nm | — |
Temperature | 700–1000 °C | — |
Temperature | 1000–2000 °C | — |
Duration | 30–120 s | — |
Duration | 900–7200 s | — |
Thickness | 2–20 nm | — |
Duration | 24–96 hours | — |
Duration | 0.5–96 hours | — |
Duration | 48–72 hours | — |
Thickness | 2–10 nm | — |
Temperature | 450–650 °C | — |
Temperature | 800–1050 °C | — |
Thickness | 0.6–1.1 nm | — |
Temperature | 200–400 °C | — |
Temperature | 150–250 °C | — |
Temperature | 500–1500 °C | — |
Temperature | 350–1500 °C | — |
Temperature | 300–700 °C | — |
Temperature | 700–1200 °C | — |
Duration | 5–16 hours | — |
Temperature | 800–1500 °C | — |
Thickness | 2–100 nm | — |
Duration | 48–96 hours | — |
Duration | 10–100 minutes | — |
Temperature | 300–800 °C | — |
Duration | 1–5 hours | — |
Thickness | 40–100 nm | — |
Thickness | 60–90 nm | — |
Thickness | 5–20 nm | — |
Thickness | 10–20 nm | — |
Thickness | 50–100 nm | — |
Thickness | 20–50 nm | — |
Thickness | 1–10 nm | — |
Thickness | ≤ 1 nm | — |
Thickness | ≤ 50 nm | — |
Thickness | ≤ 20 nm | — |
Thickness | ≤ 10 nm | — |
Thickness | ≤ 7 nm | — |
Thickness | ≥ 20 nm | — |
Thickness | ≥ 30 nm | — |
Thickness | ≥ 50 nm | — |
Thickness | ≥ 1 nm | — |
Thickness | 0.34–100 nm | — |
Thickness | 0.5–100 nm | — |
Thickness | 5–200 nm | — |
Thickness | 10–100 nm | — |
Thickness | 2–200 nm | — |