Interconnected corrugated carbon-based network

Patent metadata

Field	Value
Publication number	US-11397173-B2
Application number	US-202016791504-A
Country	US
Kind code	B2
Filing date	Feb 14, 2020
Priority date	Dec 21, 2011
Publication date	Jul 26, 2022
Grant date	Jul 26, 2022

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.

First claim

What is claimed is:

1. A method of producing a patterned interconnected corrugated carbon-based network, comprising:
a) receiving a substrate having a carbon-based oxide film;
b) generating a light beam having a power of about 5 mW to about 350 mW and a frequency of about 660 nm to about 780 nm with a laser to reduce and expand portions of the carbon-based oxide film to form a plurality of expanded and interconnected carbon layers that are electrically conductive, wherein electrical conductivity of the plurality of expanded and interconnected carbon layers is tuned according to the power of the light beam; and
c) directing the light beam across the carbon-based oxide film in a predetermined pattern of the plurality of expanded and interconnected carbon layers via a computerized control system.

2. The method of claim 1 , wherein the plurality of expanded and interconnected carbon layers has a sheet resistance that is tunable within a range of 20 megaohms per square to 80 ohms per square.

3. The method of claim 1 , wherein the carbon-based oxide film is a graphite oxide film.

4. The method of claim 3 , wherein the light beam forms the predetermined pattern of the plurality of expanded and interconnected carbon layers within the carbon-based oxide film that is repeated over predetermined portions of the predetermined pattern to increase a graphite oxide to a carbon-based oxide ratio.

5. The method of claim 1 , wherein the plurality of expanded and interconnected carbon layers has a carbon-to-oxygen (C/O) ratio that ranges from 100:1 to 25:1.

6. The method of claim 1 , wherein the light beam is a laser beam.

7. The method of claim 1 , wherein a light beam emission ranges from near infrared to ultraviolet wavelengths.

8. The method of claim 1 , further including loading the substrate into an automated laser patterning system before generating the light beam having the power density sufficient to reduce portions of the carbon-based oxide film to the patterned interconnected corrugated carbon-based network.

9. The method of claim 1 , further including an initial step of drop-casting a carbon-based oxide solution onto the substrate.

10. The method of claim 1 , wherein the substrate is polyethylene terephthalate (PET).

11. The method of claim 1 , further including exposing the substrate with oxygen plasma for about three minutes.

12. The method of claim 1 , wherein each of the expanded and interconnected carbon layers is a single corrugated carbon sheet.

13. The method of claim 1 , wherein the plurality of expanded and interconnected carbon layers yields an electrical conductivity that is greater than about 1500 S/m.

14. The method of claim 1 , wherein a range of thickness of the plurality of expanded and interconnected carbon layers is from about 7 μm to about 8 μm.

15. The method of claim 1 , wherein a number of expanded and interconnected carbon layers in the plurality of expanded and interconnected carbon layers is greater than about 100.

16. The method of claim 1 , wherein the predetermined pattern defines a scaffold for direct growth of nanoparticles.

17. The method of claim 16 , wherein the nanoparticles are platinum (Pt) nanoparticles.

18. A method of producing a patterned interconnected corrugated carbon-based network, comprising:
a) receiving a substrate having a carbon-based oxide film;
b) generating a light beam having a power of about 5 mW to about 350 mW and a diameter of about 0.7 μm to about 1 μm with a laser to reduce and expand portions of the carbon-based oxide film to form a plurality of expanded and interconnected carbon layers that are electrically conductive, wherein electrical conductivity of the plurality of expanded and interconnected carbon layers is tuned according to the power of the light beam; and
c) directing the light beam across the carbon-based oxide film in a predetermined pattern of the plurality of expanded and interconnected carbon layers via a computerized control system.

Assignees

• Univ California

Inventors

• Strong Veronica
• El-Kady Maher F
• Kaner Richard B

Classifications

• B32B9/041

  of metal · CPC title

• B32B3/28

  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 title

• Y02A50/20

  Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters · CPC title

• G01N33/0037 Primary

  NOx · CPC title

• B32B2457/12

  Photovoltaic modules · CPC title