Graphene-Copper Composite Foil for Ultra-High Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for improving the electrical conductivity of copper-based materials have reached physical limits, with high-purity copper production becoming costly and complex, and the addition of alloy materials often leading to decreased conductivity due to lattice distortion.
Innovation Solution
A graphene copper composite material preparation method combining hot pressing sintering and chemical vapor deposition (CVD) is used, where multi-layers of copper foils are hot pressed with graphene thin films deposited using methane as a carbon source, resulting in a composite material with enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-purity copper is produced by improving purity, reducing grain boundaries, and reducing defects, then electrical conductivity is improved, but cost increases significantly and technical requirements become more rigorous
Solution Approach 1:
The patent uses graphene-copper composite materials to achieve ultra-high conductivity (108%-118% IACS). The composite structure combines copper's high conductivity with graphene's exceptional electrical properties, surpassing pure copper's physical limits while avoiding the high costs and technical complexities of producing ultra-high purity copper through traditional refining methods.
Solution Approach 2:
The patent changes the material composition parameter by introducing graphene into the copper matrix. This compositional change enables the material to achieve conductivity levels (108%-118% IACS) that exceed what can be obtained through pure copper refinement, effectively changing the approach from purity optimization to composite material design.
2Strength
If alloy materials (such as tin, rare earth elements) are added to improve copper properties, then certain performance aspects are improved, but electrical conductivity decreases due to unstable processes or lattice distortion
Solution Approach 1:
The patent employs graphene-copper composites instead of traditional alloying with tin or rare earth elements. Graphene reinforces the copper matrix and enhances conductivity simultaneously, avoiding the lattice distortion and conductivity degradation that occur with conventional alloying approaches.
Solution Approach 2:
The patent introduces graphene as a localized reinforcement phase within the copper matrix. This localized addition provides mechanical strength enhancement without the widespread lattice distortion caused by bulk alloying, maintaining stable electrical conductivity while improving mechanical properties.
3Reliability
If silver is used as conductive material instead of copper, then electrical conductivity is improved, but cost increases significantly
Solution Approach 1:
The patent develops graphene-copper composites that achieve 108%-118% IACS conductivity, surpassing pure copper and approaching silver's performance. This provides a cost-effective alternative to silver by combining copper's low cost with graphene's high conductivity, achieving ultra-high conductivity without silver's prohibitive cost.
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 achieves electrical conductivity between 108% and 118% of the International Annealed Copper Standard (IACS), with a density of ≥99.8% and thermal conductivity of 400 W/(m·k), while reducing temperature rise and improving efficiency in applications such as flat-panel transformers.
Implementation Method 1
preparing a graphene thin film on the surface of the copper foil by means of a chemical vapor deposition (CVD) process with methane as a carbon source
Implementation Method 2
performing hot pressing sintering forming on the graphene copper raw material by means of a hot pressing sintering process
Data Source
AI summary
A graphene copper composite material preparation method based on a combination of hot pressing sintering and chemical vapor deposition, comprising: presetting multi-layer copper foil in a hot pressing chamber; preparing a graphene thin film on the surface of the copper foil by means of a chemical vapor deposition method to obtain a graphene copper composite material; and then performing hot pressing forming on the multi-layer graphene copper foil material to prepare the graphene copper composite material. Said material can replace a traditional copper material or silver material, is applied to a supercapacitor or a motor driving device, and has the effects of improving efficiency, reducing temperature rise, etc.