Interconnected corrugated carbon-based network

• US 10,648,958 B2
• Filed: 02/08/2017
• Issued: 05/12/2020
• Est. Priority Date: 12/21/2011
• Status: Active Grant

• Current Assignee: Regents of the University of California (University of California)
• Original Assignee: Regents of the University of California (University of California)
• Inventors: Strong, Veronica A., El-Kady, Maher F., Kaner, Richard Barry
• Primary Examiner(s): Raymond, Brittany L
• Application Number:
  US15/427,210
• Publication Number:
  US 20170299563A1
• Time in Patent Office: 1,189 Days
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2307/75 Printability
• CPC Class Codes: B32B 2429/02 Records or discs
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 2457/08 PCBs, i.e. printed circuit boards
• CPC Class Codes: B32B 2457/10 Batteries
• CPC Class Codes: B32B 2457/12 Photovoltaic modules
• CPC Class Codes: B32B 2457/20 Displays, e.g. liquid crystal displays, plasma displays
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B32B 9/041 of metal
• CPC Class Codes: B32B 9/045 of synthetic resin
• CPC Class Codes: C01B 32/23 Oxidation
• CPC Class Codes: C04B 2237/086 Carbon interlayers
• CPC Class Codes: C04B 2237/363 Carbon
• CPC Class Codes: C04B 2237/592 whereby the interlayer is not continuous, e.g. not the whole surface of the smallest substrate is covered by the interlayer
• CPC Class Codes: C04B 2237/72 : Forming laminates or joined articles comprising at least two interlayers directly next to each other
• CPC Class Codes: G01N 33/0037 : NOx
• CPC Class Codes: G21K 5/02 : having no beam-forming means
• CPC Class Codes: H01B 1/04 : mainly consisting of carbon-silicon compounds, carbon or silicon
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters

Abstract

An interconnected corrugated carbon-based network comprising a plurality of expanded and interconnected carbon layers is disclosed. In one embodiment, each of the expanded and interconnected carbon layers is made up of at least one corrugated carbon sheet that is one atom thick. In another embodiment, each of the expanded and interconnected carbon layers is made up of a plurality of corrugated carbon sheets that are each one atom thick. The interconnected corrugated carbon-based network is characterized by a high surface area with highly tunable electrical conductivity and electrochemical properties.

Claims

1. A patterned interconnected corrugated carbon-based network comprising:

a plurality of expanded and interconnected carbon layers having an oxygen content of no more than about 5% as determined by X-ray photoelectron spectroscopy (XPS) and a surface area that is greater than 1000 square meters per gram (m²/g).

2. The patterned interconnected corrugated carbon-based network of claim 1, wherein each of the expanded and interconnected carbon layers comprises at least one corrugated carbon sheet that is one atom thick.

3. The patterned interconnected corrugated carbon-based network of claim 1, wherein the plurality of expanded and interconnected carbon layers yields an electrical conductivity that is greater than about 1500 S/m.

4. The patterned interconnected corrugated carbon-based network of claim 1, wherein a second order disordered (2D) Raman peak for the patterned interconnected corrugated carbon-based network shifts from around about 2730 cm⁻

1 to around about 2688 cm<sup>−

1</sup> after the patterned interconnected corrugated carbon-based network is reduced from a carbon-based oxide.

5. The patterned interconnected corrugated carbon-based network of claim 1, wherein a 2D Raman peak for the patterned interconnected corrugated carbon-based network shifts from around about 2700 cm⁻

1 to around about 2600 cm<sup>−

1</sup> after the patterned interconnected corrugated carbon-based network is reduced from a carbon-based oxide.

6. The patterned interconnected corrugated carbon-based network of claim 1, wherein a range of thickness of the plurality of expanded and interconnected carbon layers is from around about 7 μ

m to around about 8 μ

m.

7. The patterned interconnected corrugated carbon-based network of claim 1, wherein the oxygen content of the plurality of expanded and interconnected carbon layers ranges from around about 1% to around about 5%, as determined by X-ray photoelectron spectroscopy (XPS).

8. The patterned interconnected corrugated carbon-based network of claim 1, wherein the plurality of expanded and interconnected carbon layers has a C/O ratio that ranges from around about 100:

1 to 25;

1, as determined by X-ray photoelectron spectroscopy (XPS).

9. The patterned interconnected corrugated carbon-based network of claim 1, wherein the plurality of expanded and interconnected carbon layers has a sheet resistance that is tunable within a range of around about 20 megaohms per square to around about 80 ohms per square.

10. The patterned interconnected corrugated carbon-based network of claim 1, wherein the plurality of expanded and interconnected carbon layers has a Raman spectroscopy S3 second order peak that ranges from around about 2920 cm⁻

1 to around about 2930 cm<sup>−

1</sup>.

11. The patterned interconnected corrugated carbon-based network of claim 1, wherein a number of carbon layers in the plurality of expanded and interconnected carbon layers is greater than about 100.

12. The patterned interconnected corrugated carbon-based network of claim 1, further comprising nanoparticles.

13. The patterned interconnected corrugated carbon-based network of claim 12, wherein the nanoparticles are platinum (Pt) nanoparticles.

14. The patterned interconnected corrugated carbon-based network of claim 13, wherein the nanoparticles have a diameter of about 5 nm to about 600 nm.

15. The patterned interconnected corrugated carbon-based network of claim 1, wherein the plurality of expanded and interconnected carbon layers has a surface area that is greater than 1400 square meters per gram (m2/g).

16. An energy storage device comprising:

a) two or more interdigitated electrodes, wherein at least one electrode comprises a patterned interconnected corrugated carbon-based network comprising a plurality of expanded and interconnected carbon layers having an oxygen content of no more than about 5% as determined by X-ray photoelectron spectroscopy (XPS) and a surface area that is greater than around about 1000square meters per gram (m²/g); and

b) a substrate.

17. The energy storage device of claim 16, wherein the two or more interdigitated electrodes are spaced at a gap of from about 250 μ

m to about 1,000 μ

m.

18. The energy storage device of claim 16, wherein the substrate is flexible.

19. The energy storage device of claim 18, wherein the substrate comprises polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, or any combination thereof.

20. The energy storage device of claim 16, provided that the energy storage device has a sheet resistance of about 3,800 ohms/sq to about 16,000 ohms/sq.