Porous materials comprising two-dimensional nanomaterials

Patent metadata

Field	Value
Publication number	US-10953467-B2
Application number	US-201515500664-A
Country	US
Kind code	B2
Filing date	Jul 31, 2015
Priority date	Aug 1, 2014
Publication date	Mar 23, 2021
Grant date	Mar 23, 2021

Abstract

According to the present invention, there are provided processes for preparing a porous composite material comprising a metal and a two-dimensional nanomaterial. In one aspect, the processes comprise the steps of: providing a powder comprising metal particles; heating the powder such that the metal particles fuse to form a porous scaffold; and forming a two-dimensional nanomaterial on a surface of the porous scaffold by chemical vapour deposition (CVD). Also provided are materials obtainable by the present processes, and products comprising said materials.

First claim

The invention claimed is:

1. A process for preparing a porous composite material comprising a metal and a two-dimensional nanomaterial comprising 1 to 20 monolayers, said process comprising the steps of:
providing a powder consisting of substantially pure metal particles, wherein an average particle size of the metal particles is from 100 nm to 100 μm;
heating the powder to a temperature from 900° C. to 1100° C. for a time period of 5 minutes to 5 hours, such that the metal particles fuse to form a porous scaffold; and
forming a two-dimensional nanomaterial on a surface of the porous scaffold by chemical vapour deposition (CVD), wherein the two-dimensional nanomaterial is formed at a temperature of from 100° C. to 1700° C.

2. The process according to claim 1 , wherein the metal particles comprise a metal which catalyses formation of the two-dimensional nanomaterial.

3. The process according to claim 1 , wherein the powder comprises particles of a transition metal.

4. The process according to claim 1 , wherein the metal particles are substantially spherical.

5. The process according to claim 1 , wherein: (i) the powder is heated in the presence of hydrogen; and/or (ii) the powder is heated in the reaction chamber of a CVD apparatus.

6. The process according to claim 1 , wherein the two-dimensional nanomaterial is formed under atmospheric pressure.

7. The process according to claim 1 , wherein the two-dimensional nanomaterial is selected from graphene, boron nitride and a transition metal chalcogenide.

8. The process according to claim 7 , wherein the two-dimensional nanomaterial is graphene.

9. The process according to claim 1 , wherein the process further comprises a step of forming a product comprising the porous composite material.

10. The process according to claim 1 , wherein the process further comprises a step of removing the metal from at least a portion of the porous composite material.

11. The process according to claim 10 , wherein the step of removing the metal comprises contacting the porous composite material with an etchant.

12. The process according to claim 10 , wherein the process comprises removing substantially all of the metal from the porous composite material, thereby forming a porous two-dimensional nanomaterial.

13. The process according to claim 12 , wherein the process further comprises a step of contacting the porous two-dimensional nanomaterial with a material which preserves the structure of the porous two-dimensional nanomaterial.

14. The process according to claim 12 , wherein the process further comprises a step of forming a product comprising the porous two-dimensional nanomaterial, optionally wherein said product is an electrical component or device.

15. The process according to claim 1 , wherein the process further comprises a step of converting the porous composite material to a composite material of reduced porosity, optionally wherein said step of converting comprises heating the porous composite material so as to reduce its porosity.

16. The process according to claim 15 , wherein the material of reduced porosity is a substantially non-porous composite material.

17. The process according to claim 15 , further comprising a step of preparing a product comprising the material of reduced porosity, optionally wherein said product is an electrical component or device.

18. A process for preparing a porous composite material comprising a metal and a two-dimensional nanomaterial comprising from 1 to 20 monolayers, said process comprising:
providing a porous scaffold, wherein the porous scaffold is obtainable by heating a powder consisting of a substantially pure metal powder to a temperature of from 900° C. to 1100° C. for a time period of 5 minutes to 5 hours, such that the metal particles fuse to form said porous scaffold, wherein an average particle size of the metal particles is from 100 nm to 100 μm; and
forming a two-dimensional nanomaterial on a surface of the porous scaffold by chemical vapour deposition (CVD), wherein the two-dimensional nanomaterial is formed at a temperature of from 100° C. to 1700° C.

Assignees

• Univ Oxford Innovation Ltd
• Babenko Vitaliy
• Grobert Nicole

Inventors

• Babenko Vitaliy
• Grobert Nicole

Classifications

• B22F1/056

  Submicron particles having a size above 100 nm up to 300 nm · CPC title

• B22F1/052

  characterised by a mixture of particles of different sizes or by the particle size distribution · CPC title

• B22F3/1146

  After-treatment maintaining the porosity (B22F3/114 takes precedence) · CPC title

• C23C16/01

  on temporary substrates, e.g. substrates subsequently removed by etching · CPC title

• C01B32/186

  by chemical vapour deposition [CVD] · CPC title