Expanded Graphite Production Using Defined-Wavelength Photon Irradiation
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Solution Overview
Problem
Existing methods for producing expanded graphite are energy-intensive and inefficient, limiting its widespread industrial applications.
Innovation Solution
A method involving intercalation of graphite with an intercalant followed by irradiation with a high-energy photon source at a defined wavelength to produce expanded graphite, achieving significant volume expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional thermal expansion or microwave heating methods are used to produce expanded graphite, then the graphite can be expanded to desired volume, but the process consumes excessive energy and is inefficient
Solution Approach 1:
The patent replaces traditional thermal heating methods (thermal expansion and microwave heating) with optical irradiation using a laser source. The laser energy directly irradiates the intercalated graphite, causing rapid localized heating and expansion without the need for bulk thermal heating or high-power microwave energy, thereby significantly reducing overall energy consumption and improving production efficiency
Solution Approach 2:
The patent utilizes the phase transition of water from liquid to vapor state. The intercalant contains water that undergoes rapid vaporization when irradiated by the laser, generating internal pressure that forces the graphite layers to separate and expand. This phase transition mechanism enables efficient expansion with lower energy input compared to direct thermal heating
2Volume of stationary object
If high temperatures are applied to expand graphite, then significant volume expansion is achieved, but the process requires prolonged heating time and high energy input
Solution Approach 1:
The patent employs pulsed laser irradiation rather than continuous heating. The laser is activated in periodic pulses that provide intense energy input in short durations, causing rapid water vaporization and graphite expansion. This periodic action achieves the desired volume expansion (over 200 times original volume) much faster than continuous thermal heating methods
Solution Approach 2:
The patent leverages the rapid phase transition of water from liquid to vapor state upon laser irradiation. The intercalant water vaporizes instantly when exposed to laser energy, generating rapid pressure increase that forces graphite layer separation. This phase transition enables achieving over 200 times volume expansion in significantly reduced time compared to traditional thermal methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces expanded graphite that is over 200 times its original volume, maintaining its unique properties and creating a porous structure suitable for various industrial uses.
Implementation Method 1
irradiating the intercalated graphite with a high energy photon source at a defined wavelength to produce expanded graphite
Implementation Method 2
causing the intercalated compounds to decompose and release gases
Implementation Method 3
The gas pressure forces the graphite layers apart, leading to a significant expansion in volume
Implementation Method 4
graphite is treated with an intercalation. This compound penetrates the layers of graphite and forms stable compounds known as graphite intercalation compounds (GICs)
Data Source
AI summary
Provided herein is a method of producing expanded graphite, the method comprising selecting a graphite; intercalating the graphite using an intercalant to produce an intercalated graphite; and irradiating the intercalated graphite with a high energy photon source at a defined wavelength to produce expanded graphite. Also provided herein is a method of producing expanded graphite comprising intercalating flake graphite using an intercalant to produce an intercalated flake graphite; and irradiating the intercalated flake graphite with a high energy photon source at a defined wavelength to produce expanded graphite.