Continuous Graphene Fiber Fabric via Chemical Bonding
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Solution Overview
Problem
Current methods for producing continuous carbon and graphite fibers are energy-intensive, expensive, and challenging due to the need for extreme temperature and atmosphere control, and result in fibers with limited mechanical, thermal, and electrical properties, particularly due to their porous and non-oriented structures.
Innovation Solution
A process involving chemically functionalized graphene sheets is used to produce continuous graphene fibers with high orientation and interconnection, achieving a fabric with exceptional mechanical, thermal, and electrical properties by aligning and chemically bonding graphene sheets, resulting in a dense and strong fiber structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional carbonization and graphitization processes are used to produce carbon/graphite fibers, then continuous fiber production is achieved, but the process becomes energy-intensive and expensive requiring extreme temperature control
Solution Approach 1:
The patent changes the fundamental processing parameters from extreme temperature carbonization (1000-3000°C) to room temperature or mild condition assembly of graphene sheets. This parameter change transforms the manufacturing process from energy-intensive to energy-efficient while maintaining continuous fiber production capability
Solution Approach 2:
The patent introduces functional groups as intermediary elements that facilitate bonding between graphene sheets at low temperatures. These functional groups act as mediators that enable chemical bonding without requiring extreme thermal energy, thus resolving the contradiction between ease of manufacture and energy consumption
2Ease of manufacture
If conventional carbonization processes are used, then carbon fibers are produced, but the fibers exhibit porous and non-oriented structures limiting mechanical and physical properties
Solution Approach 1:
The patent applies preliminary alignment and functionalization of graphene sheets before assembly into fibers. By pre-orienting the sheets and introducing functional groups in advance, the resulting fibers achieve high tensile strength and dense structure without requiring extreme processing conditions
Solution Approach 2:
The patent creates a composite structure where functionalized graphene sheets are chemically bonded together to form a unified fiber matrix. This composite approach eliminates porosity and achieves superior tensile strength by integrating multiple sheets into a coherent structural unit
3Strength
If high temperature graphitization is applied to increase carbon content and degree of graphitization, then higher Young's modulus and strength are achieved, but the process time increases to 1-4 hours under ultra-high temperature conditions
Solution Approach 1:
The patent replaces thermal energy input with chemical bonding mechanisms to achieve fiber consolidation. Instead of using heat to drive graphitization and strengthen fibers, the invention uses functional group chemistry to bond sheets together at room temperature, eliminating the 1-4 hour high-temperature processing step while achieving comparable or superior mechanical properties
4Ease of manufacture
If multiple CNTs or CNFs are twisted into fiber yarns, then yarns are formed, but they are not considered continuous fibers as they are mechanically fastened aggregates rather than self-bonded structures
Solution Approach 1:
The patent merges individual graphene sheets into a unified continuous fiber through chemical bonding. By combining sheets at the molecular level via functional groups rather than mechanical twisting, the invention creates true continuous fibers with inherent structural integrity and reliability, eliminating the discontinuity inherent in aggregated nanotube yarns
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 graphene-based fibers exhibit significantly higher tensile strength, elastic modulus, and conductivity compared to conventional fibers, enabling the creation of multi-functional fabrics with improved packing factors and performance in composite applications.
Implementation Method 1
chemically functionalized graphene sheets that are chemically bonded or interconnected with one another
Implementation Method 2
mechanical shear stress-induced alignment of the chemically functionalized graphene sheets along the fiber axis direction
Data Source
AI summary
A process for producing a fabric comprising at least a graphene-based continuous or long fiber, comprising: (a) preparing a graphene dispersion having chemically functionalized graphene sheets dispersed in a fluid; (b) dispensing, depositing, and shearing at least a continuous or long filament of the graphene dispersion onto a substrate, and removing the fluid to form a continuous or long fiber comprising aligned chemically functionally graphene sheets; and (c) inducing chemical reactions between chemical functional groups attached to adjacent graphene sheets to form the graphene fiber; (d) combining the graphene fiber with a plurality of fibers, the same type as or different than the graphene fiber, to form at least one fiber yarn; and (e) combining the at least one fiber yarn and a plurality of fiber yarns, the same type as or different than the at least one fiber yarn, to form the fabric.