Electrochemical Graphene Flake Production With Sub-10-Layer Thickness

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing graphene often result in materials with thicknesses exceeding 10 layers, leading to reduced electrical and thermal conductivity, mechanical strength, and specific surface area, which are not ideal for applications requiring graphene-like properties.

Innovation Solution

An electrochemical expansion method using a diamond-containing cathode and controlled electrolysis to produce graphene flakes with an average thickness of 10 atomic layers or less, utilizing a container with a rotating separator to ensure uniform treatment and high specific surface area.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional expansion methods are used, then production efficiency is improved, but graphene flake thickness exceeds 10 layers leading to reduced electrical and thermal conductivity

Engineering Contradiction:

Improveproduction efficiencyVSAvoidelectrical and thermal conductivity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention changes the electrochemical parameters by applying controlled voltage (5-60V) and using specific electrolytes to achieve precise thickness control of graphene flakes at 10 layers or less, maintaining excellent electrical and thermal conductivity while ensuring scalable production

Inventive Principle:

Principle #35Parameter changes

2Productivity

If conventional expansion methods are used, then production efficiency is improved, but mechanical strength is reduced

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmechanical strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The invention optimizes electrochemical expansion parameters including voltage control (5-60V), electrolyte composition, and treatment time to produce graphene flakes with thickness of 10 layers or less, preserving the sp2 hybridized carbon structure and maintaining high mechanical strength while enabling efficient production

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional expansion methods are used, then production efficiency is improved, but specific surface area is reduced

Engineering Contradiction:

Improveproduction efficiencyVSAvoidspecific surface area

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The invention controls the electrochemical expansion process by adjusting voltage (5-60V), electrolyte type, and treatment duration to achieve graphene flakes with thickness of 10 atomic layers or less, maximizing specific surface area while maintaining scalable production efficiency

Inventive Principle:

Principle #35Parameter changes

4Reliability

If thickness is reduced to 10 layers or less, then electrical and thermal conductivity is improved, but production complexity increases

Engineering Contradiction:

Improveelectrical and thermal conductivityVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention replaces complex mechanical exfoliation methods with a simplified electrochemical expansion process using controlled voltage application and electrolyte treatment, achieving precise thickness control at 10 layers or less while reducing production process complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses controllable electrochemical parameters (voltage 5-60V, electrolyte composition, treatment time) to achieve precise thickness control of graphene flakes, simplifying the production process while maintaining excellent electrical and thermal conductivity

Inventive Principle:

Principle #35Parameter changes

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 produces high-quality graphene flakes with excellent mechanical strength, electrical conductivity, and high specific surface area, maintaining graphene-like properties while minimizing AB-stacked layer signatures.

Implementation Method 1

applying an electrical voltage to at least one anode and at least one cathode so that the graphite is expanded, wherein the cathode contains or consists of diamond and hydrogen is produced at the cathode

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Implementation Method 2

Hydrogen can be intercalated in the graphite particles and/or chemisorbed on the graphite particles, so that graphene flakes are exfoliated from the graphite particles

Methodology Applied

Scientific EffectHydrogen intercalation: Absorption (physical)

Implementation Method 3

utilizing a container with a rotating separator to ensure uniform treatment and high specific surface area

Methodology Applied

Scientific EffectMechanical rotation:

Data Source

PatentUS20250320610A1Graphene and the production of graphene

Publication Date: 2025.10.16 AVADAIN LLC

AI summary

Compositions comprising hydrogenated and dehydrogenated graphite comprising a plurality of flakes. At least one flake in ten has a size in excess of ten square micrometers. For example, the flakes can have an average thickness of 10 atomic layers or less.