Sacrificial-Template Synthesis of 3D Graphene for Battery Anodes

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Solution Overview

Problem

Current methods for producing graphene sheets and multi-stacks are costly, time-consuming, and result in flat, smooth, defect-free materials that are not suitable for decoration and limit their applications due to morphological limitations, particularly in lithium-ion batteries where the long and thin nature of graphene sheets hinders performance.

Innovation Solution

A novel method using a sacrificial-template based approach to synthesize three-dimensional graphene structures with controlled morphology, enabling the formation of non-planar graphene sheets and multi-stacks with surface defects, allowing for decoration and improved morphological versatility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If chemical-vapor deposition is used to form graphene sheets on copper metal plate, then graphene sheets can be produced, but the production cost exceeds 3000 USD/kilogram and the process is time-consuming

Engineering Contradiction:

Improvegraphene sheet qualityVSAvoidproduction cost and time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent uses disposable copper foil as a sacrificial substrate for graphene growth. The copper foil is intentionally designed to be consumed during the lifting-off process, eliminating the need for complex retrieval systems and reducing overall production costs despite the high cost of copper material.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent discards the copper substrate after graphene deposition to release the graphene sheets. This sacrificial substrate approach simplifies the manufacturing process by eliminating the need for complex graphene retrieval systems, thereby reducing production time and costs.

Inventive Principle:

Principle #34Discarding and recovering

2Manufacturing precision

If traditional methods are used to produce graphene sheets, then flat smooth platelets are obtained, but the material lacks surface defects necessary for decoration

Engineering Contradiction:

Improvegraphene sheet uniformityVSAvoiddecoration capability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent introduces localized surface defects and variations in the graphene structure by controlling deposition conditions and using patterned substrates. These local imperfections serve as anchoring sites for decoration while maintaining the overall quality of the graphene sheets for their intended applications.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent pre-introduces surface defects and functional groups during the graphene synthesis process by controlling deposition parameters and using treated substrates. This preliminary creation of anchoring sites eliminates the need for subsequent complex surface modification steps.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If long and thin graphene sheets are used as anodes in lithium-ion batteries, then the structure is simple, but lithium ion travel distance is long causing aggregation and clogging at edges

Engineering Contradiction:

Improveanode structure simplicityVSAvoidlithium ion transport efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent divides long graphene sheets into smaller segments or uses curved/graphitized structures to reduce the effective travel distance for lithium ions. This segmentation maintains structural simplicity while significantly improving ion transport efficiency by eliminating long diffusion paths.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from flat 2D graphene sheets to 3D curved or graphitized structures. This dimensional change creates shorter diffusion paths and prevents ion aggregation at edges by distributing ions across multiple spatial dimensions, thereby improving transport efficiency without complicating the overall anode design.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 produces cost-effective, decoratable graphene materials with enhanced surface area and morphology, suitable for various applications including lithium-ion batteries, electro- and heterogeneous catalysis, and supercapacitors, addressing the limitations of traditional graphene anodes by facilitating better lithium ion accommodation and reducing clogging issues.

Implementation Method 1

The sacrificial template is then removed, for example by chemical etching, thereby enabling the formation of three-dimensional graphene structures with a specific desired morphology

Methodology Applied

Scientific EffectChemical etching:

Data Source

PatentUS10826109B2Graphene materials with controlled morphology

Publication Date: 2020.11.03 UNM RAINFOREST INNOVATIONS

AI summary

Novel non-planar non-contiguous graphene structures and novel methods for forming the same. According to some embodiments the novel methods result in three-dimensional graphene structures. According to a further embodiment these three-dimensional graphene structures have a specific, controlled morphology. According to a still further method the novel method results in decoratable graphene sheets or three-dimensional graphene structures.