3D Graphene Nanostructures via Coaxial Core-Shell Flow
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Solution Overview
Problem
Existing methods for producing three-dimensional graphene-based structures face challenges such as agglomeration in polymeric matrices, decreased electrical conductivity and surface area, uncontrolled size and shape, and limited production capacity, which hinder their application in technologies like electrodes and nanocomposites.
Innovation Solution
A coaxial multilayer core-shell production process using a coaxial flow system with immiscible fluids, where a graphene-based material and polymeric material are used to create three-dimensional closed nano-/microstructures with controlled size and shape, preventing restacking and agglomeration through a tailored C/O ratio and polymerization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to produce three-dimensional graphene structures, then production can be achieved, but the graphene sheets agglomerate in polymeric matrices and solutions leading to decreased electrical conductivity and surface area
Solution Approach 1:
The patent uses a template-assisted approach where spherical templates (such as polymeric microspheres or colloidal particles) serve as intermediaries to organize graphene sheets into three-dimensional structures. The templates prevent direct contact between graphene sheets, thereby preventing agglomeration while maintaining electrical conductivity and surface area. After structure formation, the templates can be removed, leaving stable three-dimensional graphene networks without agglomeration.
Solution Approach 2:
The patent applies different treatments to different regions of the graphene structure. By controlling the local arrangement of graphene sheets around the spherical templates, the method maintains high electrical conductivity in the network structure while preventing agglomeration at the sheet level. The local quality of the graphene arrangement is optimized to balance conductivity and structural stability.
2Manufacturing precision
If conventional synthesis methods are used, then three-dimensional graphene structures can be formed, but the size and shape remain uncontrolled
Solution Approach 1:
The patent employs pre-formed spherical templates with controlled sizes and shapes before introducing the carbon source. By preparing the templates in advance with precise dimensional control, the method achieves manufacturing precision in the final three-dimensional graphene structures. The templates are synthesized or selected beforehand to have specific size distributions and spherical shapes, which are then replicated in the graphene structures.
3Productivity
If template-based methods are used to produce hollow graphene spheres, then shape control is achieved, but production capacity is limited and cost is high
Solution Approach 1:
The patent uses inexpensive, easily synthesizable polymeric microspheres or colloidal particles as temporary templates. These templates are designed to be low-cost and disposable, eliminating the need for expensive metal templates or complex template recovery processes. The templates are removed after structure formation, and their low cost enables high-volume production without significantly increasing manufacturing costs.
4Area of stationary object
If graphene sheets are used in bulk systems, then they provide good conductive properties, but the sheets restack after reduction process decreasing surface area
Solution Approach 1:
The patent transforms the two-dimensional graphene sheets into three-dimensional structures by arranging them around spherical templates. This dimensional transformation prevents the sheets from restacking in the conventional planar manner. The three-dimensional network architecture maintains large surface area by distributing graphene sheets in spatial configurations that prevent restacking, while still providing effective conduction pathways.
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
This method enables the reproducible and cost-effective production of three-dimensional closed graphene-based nano-/microstructures with optimal electrical conductivity and surface area, allowing for alignment of graphene sheets and preventing agglomeration, thus enhancing their utility in energy storage devices and other applications.
Implementation Method 1
a second fluid (2) which is immiscible with the first fluid (1) under the conditions where said production method is conducted
Implementation Method 2
a coaxial flow system (100) having a first flow path (101) and a first fluid exit (1011) at an end of said first flow path; and a second flow path (102) circumferentially surrounding said first flow path
Implementation Method 3
said second fluid (2) comprises a graphene-based material, a polymeric material and solvent
Data Source
Figure 1
AI summary
The present invention proposes a production method for obtainment of three-dimensional closed graphene-based nano-/microstructures (10) using a coaxial multilayer core-shell production process (1000) comprising a coaxial flow system (100) having a first flow path (101) and a first fluid exit (1011) at an end of said first flow path; and a second flow path (102) circumferentially surrounding said first flow path (101), said second flow path having a second fluid exit (1021); wherein a first fluid (1) flows through the first flow path and exits through the first fluid exit (1011); and a second fluid (2) which is immiscible with the first fluid (1) under the conditions where said production method is conducted, flows through the second flow path (102) and exits through the second fluid exit (1021) such that the second fluid (2) circumferentially covers the first fluid (1) upon leaving the coaxial flow system (100); said second fluid (2) comprises a graphene-based material, a polymeric material and solvent.