Metal Matrix Nanocomposite with Oriented Graphene Sheets
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Solution Overview
Problem
Existing methods for producing graphene-metal nanocomposites face challenges such as graphene sheet damage, poor dispersion, agglomeration, lack of control over orientation, and limited volume fraction of graphene in the metal matrix, leading to suboptimal mechanical, thermal, and electrical properties.
Innovation Solution
A process involving the preparation of a graphene dispersion, aligning graphene sheets on a substrate, and depositing a metal layer to form a metal matrix nanocomposite with graphene sheets substantially parallel to each other, achieving high volume fractions and improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ball milling is used to produce graphene-metal nanocomposites, then graphene sheets can be dispersed in metal particles, but the graphene sheets suffer from size reduction and damage
Solution Approach 1:
The patent replaces the mechanical ball milling process with a chemical vapor deposition (CVD) method. Graphene sheets are grown directly on metal particles through CVD, eliminating the need for mechanical grinding and thus preventing graphene sheet damage while achieving uniform dispersion in the metal matrix.
2Quantity of substance
If ball milling is used to disperse graphene sheets, then some dispersion is achieved, but control over graphene sheet orientation is lost
Solution Approach 1:
The patent performs preliminary alignment of graphene sheets on a substrate before transferring them to the metal matrix. This preliminary action ensures that graphene sheets are oriented in a specific direction prior to incorporation into the metal composite, enabling controlled orientation that enhances anisotropic properties.
3Ease of manufacture
If traditional methods are used to produce graphene-metal nanocomposites, then production is feasible, but the volume fraction of graphene in the metal matrix is limited
Solution Approach 1:
The patent extracts graphene sheets from their growth substrate and directly transfers them onto metal particles or into the metal matrix. This extraction and direct transfer method eliminates the need for intermediate processing steps that typically limit graphene loading, enabling high volume fractions of graphene (up to 90 wt% or more) in the final composite.
4Ease of manufacture
If expanded graphite is used as input material for ball milling, then graphene composites can be produced, but additional drying steps are required which cause nanoscale agglomeration
Solution Approach 1:
The patent replaces the ball milling process that requires drying steps with a CVD-based method. Graphene is grown directly on metal particles in a controlled atmosphere, eliminating the need for subsequent drying operations that would cause nanoscale agglomeration of graphene particles.
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 nanocomposite exhibits enhanced tensile strength, thermal conductivity, and electrical conductivity, with graphene sheets aligned parallel to each other, achieving properties like tensile strength of at least 300 MPa, thermal conductivity of 500 W/mK, and electrical conductivity of 5,000 S/cm.
Implementation Method 1
electrochemically or chemically deposit a thin layer of a metal or metal alloy onto surfaces of the graphene sheets
Implementation Method 2
electrochemically or chemically deposit a thin layer of a metal or metal alloy onto surfaces of the graphene sheets
Implementation Method 3
consolidating the layer of metal-coated graphene sheets into a metal matrix nanocomposite
Data Source
AI summary
Provided is a metal matrix nanocomposite comprising: (a) a metal or metal alloy as a matrix material; and (b) multiple graphene sheets that are dispersed in said matrix material, wherein said multiple graphene sheets are substantially aligned to be parallel to one another and are in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the chemically functionalized graphene is not graphene oxide. The metal matrix exhibits a combination of exceptional tensile strength, modulus, thermal conductivity, and/or electrical conductivity.