Graphene Production via CVD and Exfoliation

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Solution Overview

Problem

Current methods for mass-producing high-quality graphene are limited by cost and scalability, restricting its industrial applications due to difficulties in achieving large-scale production of pristine graphene with high length-thickness ratio and electrical conductivity.

Innovation Solution

A method involving the use of exfoliating agents, such as oligomers or polymers with ether groups and aromatic functional groups, to create a suspension of graphite, followed by sonication and mechanical milling, which results in high-yield, high-quality graphene with a length-thickness ratio greater than 10 and excellent electrical conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical exfoliation is used to obtain high-quality graphene, then purity and quality are improved, but production quantity and scalability deteriorate

Engineering Contradiction:

Improvegraphene qualityVSAvoidproduction quantity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces mechanical exfoliation with chemical vapor deposition (CVD) growth method to produce graphene. This substitution enables scalable production while maintaining high quality, as CVD can grow large-area graphene films on substrates with controlled crystal structure and minimal defects, overcoming the low yield limitation of mechanical methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent optimizes CVD process parameters including temperature gradients, gas flow rates, and precursor ratios to control graphene nucleation and growth. By carefully controlling these parameters, high-quality graphene with large lateral dimensions can be produced at scale, resolving the contradiction between quality and quantity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If chemical exfoliation with solvents is used to increase production, then quantity is improved, but difficulty of removing solvents and maintaining purity deteriorates

Engineering Contradiction:

Improveproduction quantityVSAvoidgraphene purity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces chemical exfoliation with CVD growth method, eliminating the need for solvent-based processing. This substitution inherently produces cleaner graphene without embedded solvents or surfactants, while enabling scalable production through continuous film growth on substrates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The CVD process is self-cleaning in nature, as graphene grows directly on the substrate without requiring external exfoliating agents. The grown graphene can be easily transferred or used in-situ, avoiding contamination issues associated with chemical exfoliation methods.

Inventive Principle:

Principle #25Self-service

3Area of stationary object

If oxidation methods are used to achieve large lateral dimensions, then area is improved, but electrical properties deteriorate

Engineering Contradiction:

Improvelateral dimensionVSAvoidelectrical conductivity

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The patent optimizes CVD growth parameters to control nucleation density and grain size, enabling growth of large-area graphene films with high electrical conductivity. By controlling temperature, pressure, and gas composition, the method achieves both large lateral dimensions and intact sp2 bonding network essential for electrical properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces oxidation-based expansion methods with CVD growth, which directly synthesizes conductive graphene without introducing oxygen functional groups. This substitution maintains the electrical properties while achieving large lateral dimensions through controlled film growth.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 production of large quantities of graphene with improved electrical properties and a higher length-thickness ratio, overcoming the limitations of existing techniques and making graphene suitable for industrial applications beyond electronics.

Implementation Method 1

exfoliation by intercalation of chemical compounds and subsequent thermal expansion of the intercalated graphite

Methodology Applied

Scientific EffectIntercalation:

Implementation Method 2

The final mechanical treatment generates the graphene powder

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

with the aid of the sonication process it is possible to obtain lateral dimensions in the order of microns

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 4

exfoliation by intercalation of chemical compounds and subsequent thermal expansion of the intercalated graphite

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP2890633B1Nanostructured carbon-based material

Publication Date: 2021.11.17 AMBROGI S A S DI LIGI SIMONE & C

AI summary

A method for the production of a nanostructured carbon-based material, a nanostructured carbon-based material obtainable with said method, and a use thereof.