Graphene-Coated Copper Composite for Ultra-Conductive Bulk Forms
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Solution Overview
Problem
Current methods for synthesizing ultra-conductive copper (UCC) face challenges such as high energy expenditure, long processing times, defects, impurities, and high costs, making it difficult to achieve bulk scale commercial production with electrical conductivity above 100% International Annealed Copper Standard (IACS).
Innovation Solution
A method involving coating metal components with single- or multi-layer graphene sheets using chemical vapor deposition or graphene ink, followed by forming a bulk metal-graphene composite through processes like hot extrusion, which distributes graphene throughout the metal matrix primarily oriented horizontally, enhancing electrical conductivity beyond conventional copper grades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (deformation processing, vapor phase processing, solidification processing) are used to synthesize ultra-conductive copper, then electrical conductivity above 100% IACS is targeted, but high energy expenditure and long processing time occur
Solution Approach 1:
The patent applies preliminary action by pre-coating copper substrates with graphene layers before final forming operations. The copper foil is first coated with a graphene slurry suspension, dried, and then sintered to form a graphene-copper composite precursor. This preliminary graphene coating is then incorporated into the final ultra-conductive copper product through controlled deformation or solidification processes, achieving >100% IACS conductivity without requiring high-energy post-processing
Solution Approach 2:
The patent utilizes parameter changes by controlling the graphene concentration, slurry viscosity, and sintering temperature to optimize the graphene-copper composite structure. By adjusting these parameters, the patent achieves optimal electrical conductivity (>100% IACS) while minimizing energy expenditure during processing, as the graphene network formation occurs during low-energy drying and sintering rather than high-energy mechanical processing
2Reliability
If conventional synthesis methods are used, then electrical conductivity above 100% IACS is targeted, but defects and impurities are introduced in the additives
Solution Approach 1:
The patent applies preliminary action by pre-coating copper substrates with graphene layers before final forming operations. The copper foil is first coated with a graphene slurry suspension, dried, and then sintered to form a graphene-copper composite precursor. This preliminary graphene coating is then incorporated into the final ultra-conductive copper product through controlled deformation or solidification processes, achieving >100% IACS conductivity without requiring high-energy post-processing
Solution Approach 2:
The patent utilizes parameter changes by controlling the graphene concentration, slurry viscosity, and sintering temperature to optimize the graphene-copper composite structure. By adjusting these parameters, the patent achieves optimal electrical conductivity (>100% IACS) while minimizing energy expenditure during processing, as the graphene network formation occurs during low-energy drying and sintering rather than high-energy mechanical processing
3Reliability
If conventional synthesis methods are used, then electrical conductivity above 100% IACS is targeted, but relatively high costs and inability to integrate with existing manufacturing units occur
Solution Approach 1:
The patent applies preliminary action by pre-coating copper substrates with graphene layers before final forming operations. The copper foil is first coated with a graphene slurry suspension, dried, and then sintered to form a graphene-copper composite precursor. This preliminary graphene coating is then incorporated into the final ultra-conductive copper product through controlled deformation or solidification processes, achieving >100% IACS conductivity without requiring high-energy post-processing
Solution Approach 2:
The patent utilizes parameter changes by controlling the graphene concentration, slurry viscosity, and sintering temperature to optimize the graphene-copper composite structure. By adjusting these parameters, the patent achieves optimal electrical conductivity (>100% IACS) while minimizing energy expenditure during processing, as the graphene network formation occurs during low-energy drying and sintering rather than high-energy mechanical processing
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 resulting ultra-conductive metal-graphene composite achieves electrical conductivity ranging from 99.3% to 105% IACS and increased ampacity, overcoming the limitations of existing UCC synthesis methods by reducing defects and processing costs while integrating with existing copper form manufacturing units.
Implementation Method 1
coating or otherwise introducing metal components with graphene
Implementation Method 2
the resultant material has ultrahigh electrical conductivity and thermal conductivity
Data Source
AI summary
A method of forming a metal-graphene composite includes coating metal components (10) with graphene (14) to form graphene-coated metal components, combining a plurality of the graphene-coated metal components to form a precursor workpiece (26), and working the precursor workpiece (26) into a bulk form (30) to form the metal-graphene composite. A metal-graphene composite includes graphene (14) in a metal matrix wherein the graphene (14) is single-atomic layer or multi-layer graphene (14) distributed throughout the metal matrix and primarily (but not exclusively) oriented with a plane horizontal to an axial direction of the metal-graphene composite.