PRODUCTION PROCESS FOR METAL MATRIX NANOCOMPOSITE CONTAINING ORIENTED GRAPHENE SHEETS | Matter42 Literature
Patent
Atlas literature
Patent
US 11,629,420 B2
PRODUCTION PROCESS FOR METAL MATRIX NANOCOMPOSITE CONTAINING ORIENTED GRAPHENE SHEETS
Aruna Zhamu, Yi-jun Lin, Bor Z. Jang
Global Graphene Group, Inc., Dayton, OH (US)·Apr. 18, 2023·US
Drawings
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1
FIG. 1 A flow chart showing the most commonly used process for producing oxidized graphene sheets that entails chemical oxidation/intercalation, rinsing, and …
FIG. 2
FIG. 2 Schematic of prior art processes for producing graphene-reinforced inorganic matrix composites.
FIG. 3
FIG. 3(A) Schematic drawing to illustrate an example of a compressing and consolidating operation (using a mold cavity cell equipped with a piston or ram) for …
FIG. 4
FIG. 4 Schematic of a system for producing metal- covered graphene sheets supported by a continuous polymer film.
FIG. 5
FIG. 5(A) Vickers hardness values of graphene-Cu nano- composites plotted as a function of the graphene volume fraction.
FIG. 6
FIG. 6 Thermal conductivity of few-layer graphene-Cu nanocomposites containing graphene sheets having an aver- age of 7.5 graphene planes.
Claims
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
1 independent · 11 dependent
1
Independentgraphene sheets (single-layer or few-layer)metal or metal alloy matrixliquid adhesive resinmetal matrix nanocomposite with oriented graphene sheets
A process for producing a metal matrix nanocomposite, said process comprising: (A) preparing a graphene dispersion comprising multiple discrete graphene sheets with chemically functional-ized graphene sheets having a chemical functional group selected from the group consisting of amidoam-ines, polyamides, aliphatic amines, modified aliphatic amines, cycloaliphatic amines, aromatic amines, anhy-drides, ketimines, diethylenetriamine (DETA), trieth-ylene-tetramine (TETA), tetraethylene-pentamine (TEPA), polyethylene polyamine, polyamine epoxy adduct, phenolic hardener, non-brominated curing agent, non-amine curatives, and combinations thereof, and dispersed in a liquid adhesive resin; (B) bringing said graphene dispersion in physical contact with a solid substrate surface and aligning said gra-phene sheets along a planar direction of said substrate surface wherein said graphene sheets are bonded to and supported by said substrate surface; (C) depositing a layer of a metal or metal alloy having a thickness from 0.5 nm to 10 µm, onto surfaces of said aligned graphene sheets to form a layer of metal-coated graphene sheets supported by said substrate surface, wherein said metal or metal alloy contains a transition metal, aluminum (Al), magnesium (Mg), tin (Sn), indium (In), lead (Pb), an alloy thereof, or a combina-tion thereof; and (D) separating said layer of metal-coated graphene sheets from said substrate surface and consolidating said layer of metal-coated graphene sheets into a metal matrix nanocomposite wherein said graphene sheets are dis-persed in said matrix material, substantially aligned to be parallel to one another, and in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein said multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene mate-rial having 0.001% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, gra-phene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein said chemically functionalized graphene is not graphene oxide.
2
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said step (B) includes a procedure selected from spraying, painting, coating, cast-ing, or printing a layer of said graphene dispersion onto said substrate surface and aligning said graphene sheets along a planar direction of said substrate surface so that said gra-phene sheets are substantially parallel to one another and are bonded to and supported by said substrate surface.
3
Dependent← claim 1
The process of claim 1, wherein said solid substrate contains a polymer film having a thickness from 5 µm to 200 µm.
4
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (B) includes a procedure (i) of feeding a continuous polymer film, as said solid substrate, from a polymer film feeder into a graphene deposition chamber containing said graphene dispersion therein and a procedure (ii) of operating the graphene deposition chamber to deposit the graphene sheets and the adhesive resin to at least a primary surface of the polymer film for forming a graphene-coated polymer film; and wherein said step (C) includes moving the graphene-coated polymer film into a metallization chamber which accommo-dates a plating solution for plating a layer of said metal or metal alloy onto the graphene-coated polymer film to obtain said layer of metal-coated graphene sheets supported on said polymer film; and said step further includes a procedure of operating a winding roller to collect layer of metal-coated graphene sheets supported on said polymer film.
5
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes immersing said graphene sheets supported on said substrate surface into a metallization chamber which accommodates a plating solution for plating a layer of said metal or metal alloy onto the graphene sheets to obtain said layer of metal-coated graphene sheets supported on said substrate surface.
6
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes operating a procedure of sputtering, physical vapor deposi-tion, chemical vapor deposition, plasma-assisted deposition, spraying, painting, coating, casting, or printing for deposit-ing said thin layer of metal or metal alloy onto said graphene sheets.
7
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 10% to 95% by volume and graphene B₂ sheets are spaced by said matrix material having an average spacing from 1 nm to 300 nm.
8
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 20% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 150 nm.
9
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 50% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 70 nm.
10
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 75% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 30 nm.
11
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain mostly single-layer graphene having an average number of layers between 1 and 2.
12
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain single-layer graphene and few-layer graphene sheets having an average number of layers less than 5. ∗ ∗ ∗ ∗ ∗
Device structures
Layer stacks claimed or described, ordered top of device to substrate.
metal matrix nanocomposite with oriented graphene sheets
graphene sheets (single-layer or few-layer)reinforcement filler (aligned, parallel)
metal or metal alloy matrixmatrix
Materials
Materials described outside the worked examples.
graphene sheets (single-layer or few-layer)
Reinforcement Filler/Claimed Channel Material
metal or metal alloy matrix
Matrix Material
liquid adhesive resin
Process steps
Additional fabrication and treatment steps described in the patent.
PRODUCTION PROCESS FOR METAL MATRIX NANOCOMPOSITE CONTAINING ORIENTED GRAPHENE SHEETS
Aruna Zhamu, Yi-jun Lin, Bor Z. Jang
Global Graphene Group, Inc., Dayton, OH (US)·Apr. 18, 2023·US
Drawings
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1
FIG. 1 A flow chart showing the most commonly used process for producing oxidized graphene sheets that entails chemical oxidation/intercalation, rinsing, and …
FIG. 2
FIG. 2 Schematic of prior art processes for producing graphene-reinforced inorganic matrix composites.
FIG. 3
FIG. 3(A) Schematic drawing to illustrate an example of a compressing and consolidating operation (using a mold cavity cell equipped with a piston or ram) for …
FIG. 4
FIG. 4 Schematic of a system for producing metal- covered graphene sheets supported by a continuous polymer film.
FIG. 5
FIG. 5(A) Vickers hardness values of graphene-Cu nano- composites plotted as a function of the graphene volume fraction.
FIG. 6
FIG. 6 Thermal conductivity of few-layer graphene-Cu nanocomposites containing graphene sheets having an aver- age of 7.5 graphene planes.
Claims
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
1 independent · 11 dependent
1
Independentgraphene sheets (single-layer or few-layer)metal or metal alloy matrixliquid adhesive resinmetal matrix nanocomposite with oriented graphene sheets
A process for producing a metal matrix nanocomposite, said process comprising: (A) preparing a graphene dispersion comprising multiple discrete graphene sheets with chemically functional-ized graphene sheets having a chemical functional group selected from the group consisting of amidoam-ines, polyamides, aliphatic amines, modified aliphatic amines, cycloaliphatic amines, aromatic amines, anhy-drides, ketimines, diethylenetriamine (DETA), trieth-ylene-tetramine (TETA), tetraethylene-pentamine (TEPA), polyethylene polyamine, polyamine epoxy adduct, phenolic hardener, non-brominated curing agent, non-amine curatives, and combinations thereof, and dispersed in a liquid adhesive resin; (B) bringing said graphene dispersion in physical contact with a solid substrate surface and aligning said gra-phene sheets along a planar direction of said substrate surface wherein said graphene sheets are bonded to and supported by said substrate surface; (C) depositing a layer of a metal or metal alloy having a thickness from 0.5 nm to 10 µm, onto surfaces of said aligned graphene sheets to form a layer of metal-coated graphene sheets supported by said substrate surface, wherein said metal or metal alloy contains a transition metal, aluminum (Al), magnesium (Mg), tin (Sn), indium (In), lead (Pb), an alloy thereof, or a combina-tion thereof; and (D) separating said layer of metal-coated graphene sheets from said substrate surface and consolidating said layer of metal-coated graphene sheets into a metal matrix nanocomposite wherein said graphene sheets are dis-persed in said matrix material, substantially aligned to be parallel to one another, and in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein said multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene mate-rial having 0.001% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, gra-phene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein said chemically functionalized graphene is not graphene oxide.
2
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said step (B) includes a procedure selected from spraying, painting, coating, cast-ing, or printing a layer of said graphene dispersion onto said substrate surface and aligning said graphene sheets along a planar direction of said substrate surface so that said gra-phene sheets are substantially parallel to one another and are bonded to and supported by said substrate surface.
3
Dependent← claim 1
The process of claim 1, wherein said solid substrate contains a polymer film having a thickness from 5 µm to 200 µm.
4
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (B) includes a procedure (i) of feeding a continuous polymer film, as said solid substrate, from a polymer film feeder into a graphene deposition chamber containing said graphene dispersion therein and a procedure (ii) of operating the graphene deposition chamber to deposit the graphene sheets and the adhesive resin to at least a primary surface of the polymer film for forming a graphene-coated polymer film; and wherein said step (C) includes moving the graphene-coated polymer film into a metallization chamber which accommo-dates a plating solution for plating a layer of said metal or metal alloy onto the graphene-coated polymer film to obtain said layer of metal-coated graphene sheets supported on said polymer film; and said step further includes a procedure of operating a winding roller to collect layer of metal-coated graphene sheets supported on said polymer film.
5
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes immersing said graphene sheets supported on said substrate surface into a metallization chamber which accommodates a plating solution for plating a layer of said metal or metal alloy onto the graphene sheets to obtain said layer of metal-coated graphene sheets supported on said substrate surface.
6
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes operating a procedure of sputtering, physical vapor deposi-tion, chemical vapor deposition, plasma-assisted deposition, spraying, painting, coating, casting, or printing for deposit-ing said thin layer of metal or metal alloy onto said graphene sheets.
7
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 10% to 95% by volume and graphene B₂ sheets are spaced by said matrix material having an average spacing from 1 nm to 300 nm.
8
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 20% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 150 nm.
9
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 50% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 70 nm.
10
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 75% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 30 nm.
11
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain mostly single-layer graphene having an average number of layers between 1 and 2.
12
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain single-layer graphene and few-layer graphene sheets having an average number of layers less than 5. ∗ ∗ ∗ ∗ ∗
Device structures
Layer stacks claimed or described, ordered top of device to substrate.
metal matrix nanocomposite with oriented graphene sheets
graphene sheets (single-layer or few-layer)reinforcement filler (aligned, parallel)
metal or metal alloy matrixmatrix
Materials
Materials described outside the worked examples.
graphene sheets (single-layer or few-layer)
Reinforcement Filler/Claimed Channel Material
metal or metal alloy matrix
Matrix Material
liquid adhesive resin
Process steps
Additional fabrication and treatment steps described in the patent.
PRODUCTION PROCESS FOR METAL MATRIX NANOCOMPOSITE CONTAINING ORIENTED GRAPHENE SHEETS
Aruna Zhamu, Yi-jun Lin, Bor Z. Jang
Global Graphene Group, Inc., Dayton, OH (US)·Apr. 18, 2023·US
Drawings
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1
FIG. 1 A flow chart showing the most commonly used process for producing oxidized graphene sheets that entails chemical oxidation/intercalation, rinsing, and …
FIG. 2
FIG. 2 Schematic of prior art processes for producing graphene-reinforced inorganic matrix composites.
FIG. 3
FIG. 3(A) Schematic drawing to illustrate an example of a compressing and consolidating operation (using a mold cavity cell equipped with a piston or ram) for …
FIG. 4
FIG. 4 Schematic of a system for producing metal- covered graphene sheets supported by a continuous polymer film.
FIG. 5
FIG. 5(A) Vickers hardness values of graphene-Cu nano- composites plotted as a function of the graphene volume fraction.
FIG. 6
FIG. 6 Thermal conductivity of few-layer graphene-Cu nanocomposites containing graphene sheets having an aver- age of 7.5 graphene planes.
Claims
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
1 independent · 11 dependent
1
Independentgraphene sheets (single-layer or few-layer)metal or metal alloy matrixliquid adhesive resinmetal matrix nanocomposite with oriented graphene sheets
A process for producing a metal matrix nanocomposite, said process comprising: (A) preparing a graphene dispersion comprising multiple discrete graphene sheets with chemically functional-ized graphene sheets having a chemical functional group selected from the group consisting of amidoam-ines, polyamides, aliphatic amines, modified aliphatic amines, cycloaliphatic amines, aromatic amines, anhy-drides, ketimines, diethylenetriamine (DETA), trieth-ylene-tetramine (TETA), tetraethylene-pentamine (TEPA), polyethylene polyamine, polyamine epoxy adduct, phenolic hardener, non-brominated curing agent, non-amine curatives, and combinations thereof, and dispersed in a liquid adhesive resin; (B) bringing said graphene dispersion in physical contact with a solid substrate surface and aligning said gra-phene sheets along a planar direction of said substrate surface wherein said graphene sheets are bonded to and supported by said substrate surface; (C) depositing a layer of a metal or metal alloy having a thickness from 0.5 nm to 10 µm, onto surfaces of said aligned graphene sheets to form a layer of metal-coated graphene sheets supported by said substrate surface, wherein said metal or metal alloy contains a transition metal, aluminum (Al), magnesium (Mg), tin (Sn), indium (In), lead (Pb), an alloy thereof, or a combina-tion thereof; and (D) separating said layer of metal-coated graphene sheets from said substrate surface and consolidating said layer of metal-coated graphene sheets into a metal matrix nanocomposite wherein said graphene sheets are dis-persed in said matrix material, substantially aligned to be parallel to one another, and in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein said multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene mate-rial having 0.001% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, gra-phene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein said chemically functionalized graphene is not graphene oxide.
2
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said step (B) includes a procedure selected from spraying, painting, coating, cast-ing, or printing a layer of said graphene dispersion onto said substrate surface and aligning said graphene sheets along a planar direction of said substrate surface so that said gra-phene sheets are substantially parallel to one another and are bonded to and supported by said substrate surface.
3
Dependent← claim 1
The process of claim 1, wherein said solid substrate contains a polymer film having a thickness from 5 µm to 200 µm.
4
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (B) includes a procedure (i) of feeding a continuous polymer film, as said solid substrate, from a polymer film feeder into a graphene deposition chamber containing said graphene dispersion therein and a procedure (ii) of operating the graphene deposition chamber to deposit the graphene sheets and the adhesive resin to at least a primary surface of the polymer film for forming a graphene-coated polymer film; and wherein said step (C) includes moving the graphene-coated polymer film into a metallization chamber which accommo-dates a plating solution for plating a layer of said metal or metal alloy onto the graphene-coated polymer film to obtain said layer of metal-coated graphene sheets supported on said polymer film; and said step further includes a procedure of operating a winding roller to collect layer of metal-coated graphene sheets supported on said polymer film.
5
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes immersing said graphene sheets supported on said substrate surface into a metallization chamber which accommodates a plating solution for plating a layer of said metal or metal alloy onto the graphene sheets to obtain said layer of metal-coated graphene sheets supported on said substrate surface.
6
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes operating a procedure of sputtering, physical vapor deposi-tion, chemical vapor deposition, plasma-assisted deposition, spraying, painting, coating, casting, or printing for deposit-ing said thin layer of metal or metal alloy onto said graphene sheets.
7
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 10% to 95% by volume and graphene B₂ sheets are spaced by said matrix material having an average spacing from 1 nm to 300 nm.
8
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 20% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 150 nm.
9
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 50% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 70 nm.
10
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 75% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 30 nm.
11
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain mostly single-layer graphene having an average number of layers between 1 and 2.
12
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain single-layer graphene and few-layer graphene sheets having an average number of layers less than 5. ∗ ∗ ∗ ∗ ∗
Device structures
Layer stacks claimed or described, ordered top of device to substrate.
metal matrix nanocomposite with oriented graphene sheets
graphene sheets (single-layer or few-layer)reinforcement filler (aligned, parallel)
metal or metal alloy matrixmatrix
Materials
Materials described outside the worked examples.
graphene sheets (single-layer or few-layer)
Reinforcement Filler/Claimed Channel Material
metal or metal alloy matrix
Matrix Material
liquid adhesive resin
Process steps
Additional fabrication and treatment steps described in the patent.
PRODUCTION PROCESS FOR METAL MATRIX NANOCOMPOSITE CONTAINING ORIENTED GRAPHENE SHEETS
Aruna Zhamu, Yi-jun Lin, Bor Z. Jang
Global Graphene Group, Inc., Dayton, OH (US)·Apr. 18, 2023·US
Drawings
Patent drawings and their descriptions. Click a drawing to enlarge it.
FIG. 1
FIG. 1 A flow chart showing the most commonly used process for producing oxidized graphene sheets that entails chemical oxidation/intercalation, rinsing, and …
FIG. 2
FIG. 2 Schematic of prior art processes for producing graphene-reinforced inorganic matrix composites.
FIG. 3
FIG. 3(A) Schematic drawing to illustrate an example of a compressing and consolidating operation (using a mold cavity cell equipped with a piston or ram) for …
FIG. 4
FIG. 4 Schematic of a system for producing metal- covered graphene sheets supported by a continuous polymer film.
FIG. 5
FIG. 5(A) Vickers hardness values of graphene-Cu nano- composites plotted as a function of the graphene volume fraction.
FIG. 6
FIG. 6 Thermal conductivity of few-layer graphene-Cu nanocomposites containing graphene sheets having an aver- age of 7.5 graphene planes.
Claims
Claims define the patent's legal scope. Independent claims stand alone; dependent claims (nested) narrow them. Click a claim to expand its dependents.
1 independent · 11 dependent
1
Independentgraphene sheets (single-layer or few-layer)metal or metal alloy matrixliquid adhesive resinmetal matrix nanocomposite with oriented graphene sheets
A process for producing a metal matrix nanocomposite, said process comprising: (A) preparing a graphene dispersion comprising multiple discrete graphene sheets with chemically functional-ized graphene sheets having a chemical functional group selected from the group consisting of amidoam-ines, polyamides, aliphatic amines, modified aliphatic amines, cycloaliphatic amines, aromatic amines, anhy-drides, ketimines, diethylenetriamine (DETA), trieth-ylene-tetramine (TETA), tetraethylene-pentamine (TEPA), polyethylene polyamine, polyamine epoxy adduct, phenolic hardener, non-brominated curing agent, non-amine curatives, and combinations thereof, and dispersed in a liquid adhesive resin; (B) bringing said graphene dispersion in physical contact with a solid substrate surface and aligning said gra-phene sheets along a planar direction of said substrate surface wherein said graphene sheets are bonded to and supported by said substrate surface; (C) depositing a layer of a metal or metal alloy having a thickness from 0.5 nm to 10 µm, onto surfaces of said aligned graphene sheets to form a layer of metal-coated graphene sheets supported by said substrate surface, wherein said metal or metal alloy contains a transition metal, aluminum (Al), magnesium (Mg), tin (Sn), indium (In), lead (Pb), an alloy thereof, or a combina-tion thereof; and (D) separating said layer of metal-coated graphene sheets from said substrate surface and consolidating said layer of metal-coated graphene sheets into a metal matrix nanocomposite wherein said graphene sheets are dis-persed in said matrix material, substantially aligned to be parallel to one another, and in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein said multiple graphene sheets contain single-layer or few-layer graphene sheets selected from a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene mate-rial having 0.001% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, gra-phene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein said chemically functionalized graphene is not graphene oxide.
2
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said step (B) includes a procedure selected from spraying, painting, coating, cast-ing, or printing a layer of said graphene dispersion onto said substrate surface and aligning said graphene sheets along a planar direction of said substrate surface so that said gra-phene sheets are substantially parallel to one another and are bonded to and supported by said substrate surface.
3
Dependent← claim 1
The process of claim 1, wherein said solid substrate contains a polymer film having a thickness from 5 µm to 200 µm.
4
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (B) includes a procedure (i) of feeding a continuous polymer film, as said solid substrate, from a polymer film feeder into a graphene deposition chamber containing said graphene dispersion therein and a procedure (ii) of operating the graphene deposition chamber to deposit the graphene sheets and the adhesive resin to at least a primary surface of the polymer film for forming a graphene-coated polymer film; and wherein said step (C) includes moving the graphene-coated polymer film into a metallization chamber which accommo-dates a plating solution for plating a layer of said metal or metal alloy onto the graphene-coated polymer film to obtain said layer of metal-coated graphene sheets supported on said polymer film; and said step further includes a procedure of operating a winding roller to collect layer of metal-coated graphene sheets supported on said polymer film.
5
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes immersing said graphene sheets supported on said substrate surface into a metallization chamber which accommodates a plating solution for plating a layer of said metal or metal alloy onto the graphene sheets to obtain said layer of metal-coated graphene sheets supported on said substrate surface.
6
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrix
The process of claim 1, wherein said step (C) includes operating a procedure of sputtering, physical vapor deposi-tion, chemical vapor deposition, plasma-assisted deposition, spraying, painting, coating, casting, or printing for deposit-ing said thin layer of metal or metal alloy onto said graphene sheets.
7
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 10% to 95% by volume and graphene B₂ sheets are spaced by said matrix material having an average spacing from 1 nm to 300 nm.
8
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 20% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 150 nm.
9
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 50% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 70 nm.
10
Dependent← claim 1graphene sheets (single-layer or few-layer)metal or metal alloy matrixmetal matrix nanocomposite with oriented graphene sheets
The process of claim 1, wherein said graphene sheets are in an amount from 75% to 95% by volume and graphene sheets are spaced by said matrix material having an average spacing from 1 nm to 30 nm.
11
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain mostly single-layer graphene having an average number of layers between 1 and 2.
12
Dependent← claim 1graphene sheets (single-layer or few-layer)
The process of claim 1, wherein said graphene sheets contain single-layer graphene and few-layer graphene sheets having an average number of layers less than 5. ∗ ∗ ∗ ∗ ∗
Device structures
Layer stacks claimed or described, ordered top of device to substrate.
metal matrix nanocomposite with oriented graphene sheets
graphene sheets (single-layer or few-layer)reinforcement filler (aligned, parallel)
metal or metal alloy matrixmatrix
Materials
Materials described outside the worked examples.
graphene sheets (single-layer or few-layer)
Reinforcement Filler/Claimed Channel Material
metal or metal alloy matrix
Matrix Material
liquid adhesive resin
Process steps
Additional fabrication and treatment steps described in the patent.
target substrate:aligned graphene sheets on substrate
Materials:metal or metal alloy matrix
4
Consolidation
Step 4
Process details
description:separating metal-coated graphene sheets from substrate and consolidating into metal matrix nanocomposite
Materials:graphene sheets (single-layer or few-layer)metal or metal alloy matrix
5–150 minutes
—
Thickness
1–200 nm
—
Thickness
1–300 nm
—
Thickness
1–150 nm
—
Thickness
1–70 nm
—
Thickness
1–30 nm
—
Thickness
5–500000 nm
—
Thickness
10–100000 nm
—
Thickness
5–100000 nm
—
Duration
3–1800 s
—
Temperature
90–150 °C
—
Duration
2–30 minutes
—
Thickness
1–10000 nm
—
Thickness
10–2000 nm
—
Duration
900–7200 s
—
Duration
15–60 seconds
—
Pressure
1–30 pa
—
Temperature
800–1050 °C
—
Temperature
0–70 °C
—
Temperature
600–1100 °C
—
Temperature
200–400 °C
—
Temperature
150–250 °C
—
Thickness
0.05–100 µm
—
Duration
30–90 seconds
—
Thickness
2–3 nm
—
Duration
30–60 minutes
—
Duration
10–50 minutes
—
Thickness
≤ 0.34 nm
—
Pressure
≤ 350 MPa
—
—
≤ 1 W
—
Pressure
≤ 500 MPa
—
—
≤ 1200 W
—
Pressure
≤ 700 MPa
—
—
≤ 1500 W
—
Pressure
≤ 800 MPa
—
—
≤ 1600 W
—
Thickness
≥ 0.6 nm
—
Temperature
≥ 31 °C
—
Pressure
≥ 7.4 MPa
—
Temperature
≥ 374 °C
—
Pressure
≥ 22.1 MPa
—
Thickness
≥ 0.1 µm
—
Temperature
≥ 70 °C
—
Duration
≥ 1 minute
—
Thickness
0.5–10000 nm
—
Thickness
5–200 µm
—
Pressure
≤ 300 MPa
—
—
≤ 500 W
—
Pressure
≤ 400 MPa
—
—
≤ 800 W
—
Pressure
≤ 600 MPa
—
examiner
US 2005/0271574 A12005/0271574 A1 12/2005 Jang et al.
US 2008/0048152 A12008/0048152 A1 2/2008 Jang et al.
US 2009/0295103 A12009/0295103 A1 * 12/2009 Ebina.................... C04B 35/536examiner
US 2010/0032409 A12010/0032409 A1 * 2/2010 Hong.................. H01L 21/3083examiner
US 2011/0133132 A12011/0133132 A1 6/2011 Zhamu et al.
US 2011/0285999 A12011/0285999 A1 * 11/2011 Kim..................... G01N 21/552examiner
US 2012/0077017 A12012/0077017 A1 3/2012 Buresch et al.
US 2013/0068521 A12013/0068521 A1 * 3/2013 Hong................... H05K 9/0081examiner
US 2014/0154464 A12014/0154464 A1 * 6/2014 Miller................ B01D 67/0062examiner
US 2014/0224466 A12014/0224466 A1 8/2014 Lin et al.
US 2015/0266739 A12015/0266739 A1 * 9/2015 Zhamu.................. C01B 32/182examiner
US 2017/0158511 A12017/0158511 A1 * 6/2017 Braley.................... B32B 3/266examiner
US 2017/0162291 A12017/0162291 A1 6/2017 Zhamu et al.
US 2017/0221643 A12017/0221643 A1 8/2017 Zhamu et al.
US 2018/0077828 A12018/0077828 A1 * 3/2018 Braley.................... B32B 5/022examiner
US 2018/0159118 A12018/0159118 A1 * 6/2018 Lee....................... H01M 4/587examiner
US 2018/0310442 A12018/0310442 A1 * 10/2018 Zhamu................... C08K 5/357examiner
US 2018/0310443 A12018/0310443 A1 * 10/2018 Hong...................... C23C 16/56examiner
US 2019/0169741 A12019/0169741 A1 * 6/2019 Farquhar................. C23C 16/26examiner
US 2019/0292671 A12019/0292671 A1 * 9/2019 Zhamu................ C23C 18/1635examiner
US 2020/0247974 A12020/0247974 A1 * 8/2020 Gao........................ D01F 1/106examiner
US 2020/0279665 A12020/0279665 A1 * 9/2020 Kim..................... C09D 11/037examiner
US 2020/0339424 A12020/0339424 A1 * 10/2020 Thomas................ C01B 32/184examiner
Cited non-patent literature · 8
PCT/US19/23958 International Search Report and Written Opinion, 20 pages.
The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis. Anderson et al., “The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis” J. Amer. Chem. Soc. (1964) vol. 86, No. 9, pp. 1839-1842.
On the Nucleation of Graphene by Chemical Vapor Deposition. Hu et. al., “On the Nucleation of Graphene by Chemical Vapor Deposition” New Journal of Chemistry (2012) vol. 36, pp. 73-77. Hummers, “Preparation of graphitic oxide” J. Am. Chem. Soc. (1958) vol. 80, p. 1339.
Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process. Hwang et al., “Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process” Advanced Materials (2013) vol. 25, pp. 6724-6729.
Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives. Karlicky et al., “Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives” ACS Nano (2013) vol. 7, No. 8, pp. 6434-6464.
Conductive enhancement of copper/graphene composites based on high-quality graphene. Li et al., “Conductive enhancement of copper/graphene composites based on high-quality graphene” Royal Society of ChemistryAdvances (2015) vol. 5, pp. 80428-80433.
Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites. Wang et al., “Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites” Materials and Design (2013) vol. 47, pp. 667-671.
target substrate:aligned graphene sheets on substrate
Materials:metal or metal alloy matrix
4
Consolidation
Step 4
Process details
description:separating metal-coated graphene sheets from substrate and consolidating into metal matrix nanocomposite
Materials:graphene sheets (single-layer or few-layer)metal or metal alloy matrix
5–150 minutes
—
Thickness
1–200 nm
—
Thickness
1–300 nm
—
Thickness
1–150 nm
—
Thickness
1–70 nm
—
Thickness
1–30 nm
—
Thickness
5–500000 nm
—
Thickness
10–100000 nm
—
Thickness
5–100000 nm
—
Duration
3–1800 s
—
Temperature
90–150 °C
—
Duration
2–30 minutes
—
Thickness
1–10000 nm
—
Thickness
10–2000 nm
—
Duration
900–7200 s
—
Duration
15–60 seconds
—
Pressure
1–30 pa
—
Temperature
800–1050 °C
—
Temperature
0–70 °C
—
Temperature
600–1100 °C
—
Temperature
200–400 °C
—
Temperature
150–250 °C
—
Thickness
0.05–100 µm
—
Duration
30–90 seconds
—
Thickness
2–3 nm
—
Duration
30–60 minutes
—
Duration
10–50 minutes
—
Thickness
≤ 0.34 nm
—
Pressure
≤ 350 MPa
—
—
≤ 1 W
—
Pressure
≤ 500 MPa
—
—
≤ 1200 W
—
Pressure
≤ 700 MPa
—
—
≤ 1500 W
—
Pressure
≤ 800 MPa
—
—
≤ 1600 W
—
Thickness
≥ 0.6 nm
—
Temperature
≥ 31 °C
—
Pressure
≥ 7.4 MPa
—
Temperature
≥ 374 °C
—
Pressure
≥ 22.1 MPa
—
Thickness
≥ 0.1 µm
—
Temperature
≥ 70 °C
—
Duration
≥ 1 minute
—
Thickness
0.5–10000 nm
—
Thickness
5–200 µm
—
Pressure
≤ 300 MPa
—
—
≤ 500 W
—
Pressure
≤ 400 MPa
—
—
≤ 800 W
—
Pressure
≤ 600 MPa
—
examiner
US 2005/0271574 A12005/0271574 A1 12/2005 Jang et al.
US 2008/0048152 A12008/0048152 A1 2/2008 Jang et al.
US 2009/0295103 A12009/0295103 A1 * 12/2009 Ebina.................... C04B 35/536examiner
US 2010/0032409 A12010/0032409 A1 * 2/2010 Hong.................. H01L 21/3083examiner
US 2011/0133132 A12011/0133132 A1 6/2011 Zhamu et al.
US 2011/0285999 A12011/0285999 A1 * 11/2011 Kim..................... G01N 21/552examiner
US 2012/0077017 A12012/0077017 A1 3/2012 Buresch et al.
US 2013/0068521 A12013/0068521 A1 * 3/2013 Hong................... H05K 9/0081examiner
US 2014/0154464 A12014/0154464 A1 * 6/2014 Miller................ B01D 67/0062examiner
US 2014/0224466 A12014/0224466 A1 8/2014 Lin et al.
US 2015/0266739 A12015/0266739 A1 * 9/2015 Zhamu.................. C01B 32/182examiner
US 2017/0158511 A12017/0158511 A1 * 6/2017 Braley.................... B32B 3/266examiner
US 2017/0162291 A12017/0162291 A1 6/2017 Zhamu et al.
US 2017/0221643 A12017/0221643 A1 8/2017 Zhamu et al.
US 2018/0077828 A12018/0077828 A1 * 3/2018 Braley.................... B32B 5/022examiner
US 2018/0159118 A12018/0159118 A1 * 6/2018 Lee....................... H01M 4/587examiner
US 2018/0310442 A12018/0310442 A1 * 10/2018 Zhamu................... C08K 5/357examiner
US 2018/0310443 A12018/0310443 A1 * 10/2018 Hong...................... C23C 16/56examiner
US 2019/0169741 A12019/0169741 A1 * 6/2019 Farquhar................. C23C 16/26examiner
US 2019/0292671 A12019/0292671 A1 * 9/2019 Zhamu................ C23C 18/1635examiner
US 2020/0247974 A12020/0247974 A1 * 8/2020 Gao........................ D01F 1/106examiner
US 2020/0279665 A12020/0279665 A1 * 9/2020 Kim..................... C09D 11/037examiner
US 2020/0339424 A12020/0339424 A1 * 10/2020 Thomas................ C01B 32/184examiner
Cited non-patent literature · 8
PCT/US19/23958 International Search Report and Written Opinion, 20 pages.
The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis. Anderson et al., “The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis” J. Amer. Chem. Soc. (1964) vol. 86, No. 9, pp. 1839-1842.
On the Nucleation of Graphene by Chemical Vapor Deposition. Hu et. al., “On the Nucleation of Graphene by Chemical Vapor Deposition” New Journal of Chemistry (2012) vol. 36, pp. 73-77. Hummers, “Preparation of graphitic oxide” J. Am. Chem. Soc. (1958) vol. 80, p. 1339.
Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process. Hwang et al., “Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process” Advanced Materials (2013) vol. 25, pp. 6724-6729.
Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives. Karlicky et al., “Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives” ACS Nano (2013) vol. 7, No. 8, pp. 6434-6464.
Conductive enhancement of copper/graphene composites based on high-quality graphene. Li et al., “Conductive enhancement of copper/graphene composites based on high-quality graphene” Royal Society of ChemistryAdvances (2015) vol. 5, pp. 80428-80433.
Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites. Wang et al., “Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites” Materials and Design (2013) vol. 47, pp. 667-671.
target substrate:aligned graphene sheets on substrate
Materials:metal or metal alloy matrix
4
Consolidation
Step 4
Process details
description:separating metal-coated graphene sheets from substrate and consolidating into metal matrix nanocomposite
Materials:graphene sheets (single-layer or few-layer)metal or metal alloy matrix
5–150 minutes
—
Thickness
1–200 nm
—
Thickness
1–300 nm
—
Thickness
1–150 nm
—
Thickness
1–70 nm
—
Thickness
1–30 nm
—
Thickness
5–500000 nm
—
Thickness
10–100000 nm
—
Thickness
5–100000 nm
—
Duration
3–1800 s
—
Temperature
90–150 °C
—
Duration
2–30 minutes
—
Thickness
1–10000 nm
—
Thickness
10–2000 nm
—
Duration
900–7200 s
—
Duration
15–60 seconds
—
Pressure
1–30 pa
—
Temperature
800–1050 °C
—
Temperature
0–70 °C
—
Temperature
600–1100 °C
—
Temperature
200–400 °C
—
Temperature
150–250 °C
—
Thickness
0.05–100 µm
—
Duration
30–90 seconds
—
Thickness
2–3 nm
—
Duration
30–60 minutes
—
Duration
10–50 minutes
—
Thickness
≤ 0.34 nm
—
Pressure
≤ 350 MPa
—
—
≤ 1 W
—
Pressure
≤ 500 MPa
—
—
≤ 1200 W
—
Pressure
≤ 700 MPa
—
—
≤ 1500 W
—
Pressure
≤ 800 MPa
—
—
≤ 1600 W
—
Thickness
≥ 0.6 nm
—
Temperature
≥ 31 °C
—
Pressure
≥ 7.4 MPa
—
Temperature
≥ 374 °C
—
Pressure
≥ 22.1 MPa
—
Thickness
≥ 0.1 µm
—
Temperature
≥ 70 °C
—
Duration
≥ 1 minute
—
Thickness
0.5–10000 nm
—
Thickness
5–200 µm
—
Pressure
≤ 300 MPa
—
—
≤ 500 W
—
Pressure
≤ 400 MPa
—
—
≤ 800 W
—
Pressure
≤ 600 MPa
—
examiner
US 2005/0271574 A12005/0271574 A1 12/2005 Jang et al.
US 2008/0048152 A12008/0048152 A1 2/2008 Jang et al.
US 2009/0295103 A12009/0295103 A1 * 12/2009 Ebina.................... C04B 35/536examiner
US 2010/0032409 A12010/0032409 A1 * 2/2010 Hong.................. H01L 21/3083examiner
US 2011/0133132 A12011/0133132 A1 6/2011 Zhamu et al.
US 2011/0285999 A12011/0285999 A1 * 11/2011 Kim..................... G01N 21/552examiner
US 2012/0077017 A12012/0077017 A1 3/2012 Buresch et al.
US 2013/0068521 A12013/0068521 A1 * 3/2013 Hong................... H05K 9/0081examiner
US 2014/0154464 A12014/0154464 A1 * 6/2014 Miller................ B01D 67/0062examiner
US 2014/0224466 A12014/0224466 A1 8/2014 Lin et al.
US 2015/0266739 A12015/0266739 A1 * 9/2015 Zhamu.................. C01B 32/182examiner
US 2017/0158511 A12017/0158511 A1 * 6/2017 Braley.................... B32B 3/266examiner
US 2017/0162291 A12017/0162291 A1 6/2017 Zhamu et al.
US 2017/0221643 A12017/0221643 A1 8/2017 Zhamu et al.
US 2018/0077828 A12018/0077828 A1 * 3/2018 Braley.................... B32B 5/022examiner
US 2018/0159118 A12018/0159118 A1 * 6/2018 Lee....................... H01M 4/587examiner
US 2018/0310442 A12018/0310442 A1 * 10/2018 Zhamu................... C08K 5/357examiner
US 2018/0310443 A12018/0310443 A1 * 10/2018 Hong...................... C23C 16/56examiner
US 2019/0169741 A12019/0169741 A1 * 6/2019 Farquhar................. C23C 16/26examiner
US 2019/0292671 A12019/0292671 A1 * 9/2019 Zhamu................ C23C 18/1635examiner
US 2020/0247974 A12020/0247974 A1 * 8/2020 Gao........................ D01F 1/106examiner
US 2020/0279665 A12020/0279665 A1 * 9/2020 Kim..................... C09D 11/037examiner
US 2020/0339424 A12020/0339424 A1 * 10/2020 Thomas................ C01B 32/184examiner
Cited non-patent literature · 8
PCT/US19/23958 International Search Report and Written Opinion, 20 pages.
The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis. Anderson et al., “The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis” J. Amer. Chem. Soc. (1964) vol. 86, No. 9, pp. 1839-1842.
On the Nucleation of Graphene by Chemical Vapor Deposition. Hu et. al., “On the Nucleation of Graphene by Chemical Vapor Deposition” New Journal of Chemistry (2012) vol. 36, pp. 73-77. Hummers, “Preparation of graphitic oxide” J. Am. Chem. Soc. (1958) vol. 80, p. 1339.
Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process. Hwang et al., “Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process” Advanced Materials (2013) vol. 25, pp. 6724-6729.
Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives. Karlicky et al., “Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives” ACS Nano (2013) vol. 7, No. 8, pp. 6434-6464.
Conductive enhancement of copper/graphene composites based on high-quality graphene. Li et al., “Conductive enhancement of copper/graphene composites based on high-quality graphene” Royal Society of ChemistryAdvances (2015) vol. 5, pp. 80428-80433.
Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites. Wang et al., “Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites” Materials and Design (2013) vol. 47, pp. 667-671.
target substrate:aligned graphene sheets on substrate
Materials:metal or metal alloy matrix
4
Consolidation
Step 4
Process details
description:separating metal-coated graphene sheets from substrate and consolidating into metal matrix nanocomposite
Materials:graphene sheets (single-layer or few-layer)metal or metal alloy matrix
5–150 minutes
—
Thickness
1–200 nm
—
Thickness
1–300 nm
—
Thickness
1–150 nm
—
Thickness
1–70 nm
—
Thickness
1–30 nm
—
Thickness
5–500000 nm
—
Thickness
10–100000 nm
—
Thickness
5–100000 nm
—
Duration
3–1800 s
—
Temperature
90–150 °C
—
Duration
2–30 minutes
—
Thickness
1–10000 nm
—
Thickness
10–2000 nm
—
Duration
900–7200 s
—
Duration
15–60 seconds
—
Pressure
1–30 pa
—
Temperature
800–1050 °C
—
Temperature
0–70 °C
—
Temperature
600–1100 °C
—
Temperature
200–400 °C
—
Temperature
150–250 °C
—
Thickness
0.05–100 µm
—
Duration
30–90 seconds
—
Thickness
2–3 nm
—
Duration
30–60 minutes
—
Duration
10–50 minutes
—
Thickness
≤ 0.34 nm
—
Pressure
≤ 350 MPa
—
—
≤ 1 W
—
Pressure
≤ 500 MPa
—
—
≤ 1200 W
—
Pressure
≤ 700 MPa
—
—
≤ 1500 W
—
Pressure
≤ 800 MPa
—
—
≤ 1600 W
—
Thickness
≥ 0.6 nm
—
Temperature
≥ 31 °C
—
Pressure
≥ 7.4 MPa
—
Temperature
≥ 374 °C
—
Pressure
≥ 22.1 MPa
—
Thickness
≥ 0.1 µm
—
Temperature
≥ 70 °C
—
Duration
≥ 1 minute
—
Thickness
0.5–10000 nm
—
Thickness
5–200 µm
—
Pressure
≤ 300 MPa
—
—
≤ 500 W
—
Pressure
≤ 400 MPa
—
—
≤ 800 W
—
Pressure
≤ 600 MPa
—
examiner
US 2005/0271574 A12005/0271574 A1 12/2005 Jang et al.
US 2008/0048152 A12008/0048152 A1 2/2008 Jang et al.
US 2009/0295103 A12009/0295103 A1 * 12/2009 Ebina.................... C04B 35/536examiner
US 2010/0032409 A12010/0032409 A1 * 2/2010 Hong.................. H01L 21/3083examiner
US 2011/0133132 A12011/0133132 A1 6/2011 Zhamu et al.
US 2011/0285999 A12011/0285999 A1 * 11/2011 Kim..................... G01N 21/552examiner
US 2012/0077017 A12012/0077017 A1 3/2012 Buresch et al.
US 2013/0068521 A12013/0068521 A1 * 3/2013 Hong................... H05K 9/0081examiner
US 2014/0154464 A12014/0154464 A1 * 6/2014 Miller................ B01D 67/0062examiner
US 2014/0224466 A12014/0224466 A1 8/2014 Lin et al.
US 2015/0266739 A12015/0266739 A1 * 9/2015 Zhamu.................. C01B 32/182examiner
US 2017/0158511 A12017/0158511 A1 * 6/2017 Braley.................... B32B 3/266examiner
US 2017/0162291 A12017/0162291 A1 6/2017 Zhamu et al.
US 2017/0221643 A12017/0221643 A1 8/2017 Zhamu et al.
US 2018/0077828 A12018/0077828 A1 * 3/2018 Braley.................... B32B 5/022examiner
US 2018/0159118 A12018/0159118 A1 * 6/2018 Lee....................... H01M 4/587examiner
US 2018/0310442 A12018/0310442 A1 * 10/2018 Zhamu................... C08K 5/357examiner
US 2018/0310443 A12018/0310443 A1 * 10/2018 Hong...................... C23C 16/56examiner
US 2019/0169741 A12019/0169741 A1 * 6/2019 Farquhar................. C23C 16/26examiner
US 2019/0292671 A12019/0292671 A1 * 9/2019 Zhamu................ C23C 18/1635examiner
US 2020/0247974 A12020/0247974 A1 * 8/2020 Gao........................ D01F 1/106examiner
US 2020/0279665 A12020/0279665 A1 * 9/2020 Kim..................... C09D 11/037examiner
US 2020/0339424 A12020/0339424 A1 * 10/2020 Thomas................ C01B 32/184examiner
Cited non-patent literature · 8
PCT/US19/23958 International Search Report and Written Opinion, 20 pages.
The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis. Anderson et al., “The Use of Esters of N-Hydroxysuccinimide in Peptide Synthesis” J. Amer. Chem. Soc. (1964) vol. 86, No. 9, pp. 1839-1842.
On the Nucleation of Graphene by Chemical Vapor Deposition. Hu et. al., “On the Nucleation of Graphene by Chemical Vapor Deposition” New Journal of Chemistry (2012) vol. 36, pp. 73-77. Hummers, “Preparation of graphitic oxide” J. Am. Chem. Soc. (1958) vol. 80, p. 1339.
Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process. Hwang et al., “Enhanced Mechanical Properties of Graphene/Copper Nanocomposites Using a Molecular-Level mixing process” Advanced Materials (2013) vol. 25, pp. 6724-6729.
Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives. Karlicky et al., “Halogenated Graphenes: Rapidly Growing Family of Graphene Derivatives” ACS Nano (2013) vol. 7, No. 8, pp. 6434-6464.
Conductive enhancement of copper/graphene composites based on high-quality graphene. Li et al., “Conductive enhancement of copper/graphene composites based on high-quality graphene” Royal Society of ChemistryAdvances (2015) vol. 5, pp. 80428-80433.
Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites. Wang et al., “Effect of the content of ball-milled expanded graphite on the bending and tribological properties of copper-graphite com- posites” Materials and Design (2013) vol. 47, pp. 667-671.