Synthesis of three-dimensional graphene foam: use as supercapacitors
First Claim
1. A method of fabricating a three-dimensional graphene crystalline foam, comprising:
- a) mixing a carbon source and a skelet powder together to obtain a uniform mixture, wherein the carbon source is optionally coated on a group IV-B element;
b) applying pressure to the uniform mixture obtained in step (a) to obtain a closed packed structure;
c) applying temperature and pressure to the closed packed structure to form a graphene sheet layered around the skelet powder and the group IV-B element if present; and
d) removing the skelet powder from the closed packed structure using a chemical bath to dissolve the skelet powder away from the closed packed structure leaving voids, resulting in a three-dimensional crystalline foam comprising graphene and optionally a group IV-B element.
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Abstract
The application discloses methods of fabricating three-dimensional (3D) graphene crystalline foam, based on mixing a carbon source with a skelet (scaffold) powder. In one embodiment heat and pressure are used to compact the carbon and a metal powder into a close packed structure. In another embodiment a 3D crystalline graphene foam is fabricated with a large surface area (550 m2/g) from a 3D metal foam, depositing a layer of graphene using chemical vapor deposition (CVD), depositing a polymer support and removing the metal via wet chemical etching, such that the graphene retains the configuration, and then finally removing the polymer. A method of fabricating the metal foam framework and coating the metal with graphene are also disclosed.
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Citations
13 Claims
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1. A method of fabricating a three-dimensional graphene crystalline foam, comprising:
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a) mixing a carbon source and a skelet powder together to obtain a uniform mixture, wherein the carbon source is optionally coated on a group IV-B element; b) applying pressure to the uniform mixture obtained in step (a) to obtain a closed packed structure; c) applying temperature and pressure to the closed packed structure to form a graphene sheet layered around the skelet powder and the group IV-B element if present; and d) removing the skelet powder from the closed packed structure using a chemical bath to dissolve the skelet powder away from the closed packed structure leaving voids, resulting in a three-dimensional crystalline foam comprising graphene and optionally a group IV-B element. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of fabricating a three-dimensional crystalline graphene foam, comprising:
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a) providing a three-dimensional metal foam framework having a surface area of at least about 500 m2/g, for fabricating a three-dimensional graphene foam; b) depositing a layer of graphene onto the metal foam of step (a) by template-directed chemical vapor deposition (CVD); c) depositing a polymer support onto the graphene layer; d) removing the three-dimensional metal foam framework via wet chemical etching, such that the graphene layer and the polymer support retain the three-dimensional configuration provided by the metal foam framework; and e) removing the polymer support using a solvent to thereby obtain the three-dimensional crystalline graphene foams wherein the metal foam framework of step (a) is fabricated by; i) mixing a metal powder and a skelet powder together to obtain a uniform mixture; ii) applying pressure to the uniform mixture of the metal powder and the skelet powder to obtain a closed packed structure; iii) applying temperature and pressure to the closed packed structure obtained in step (ii) to melt the metal powder around the skelet powder; and iv) removing the skelet powder using a chemical bath to dissolve the skelet powder away from the closed packed structure leaving voids, resulting in a metal foam. - View Dependent Claims (10, 11, 12, 13)
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Specification