Hybrid ionic graphene nanocomposite with layered structure

Abstract

A material can have a layered structure with at least a first layer, including a carbon-based material or a substrate of a material other than a carbon-based material, a second layer, including a carbon-based material, and a third, intermediate layer that separates and interconnects the first and second layers. The carbon-based material includes at least 50 at. % carbon, has a hexagonal lattice and the layer or layers including the carbon-based material has/have a thickness of 1-20 times the size of a carbon atom. The intermediate layer is a layer that includes a salt having ions that include at least two separate cyclic, planar groups that are capable of forming π-π-stacking with the material of the second layer and that the third, intermediate layer is connected to at least the second layer by π-π-stacking caused by said cyclic planar groups of the salt ions.

Claims

1. A nanocomposite material comprising a first layer, a second layer comprising a carbon-based material and an intermediate layer that separates and interconnects the first and second layers, wherein said carbon-based material comprises at least 50 atomic percent carbon, has a hexagonal lattice and wherein the second layer has a thickness of 1-20 times the size of a carbon atom, wherein the intermediate layer comprises a salt that has ions comprising at least two separate cyclic, planar groups that are capable of forming π-π-stacking interaction with at least the second layer.

2. The nanocomposite material according to claim 1, wherein the cyclic planar groups of said ions of said salt comprise at least one aromatic group.

3. The nanocomposite material according to claim 1, wherein each of said cyclic planar groups of said ions of said salt is an aromatic group.

4. The nanocomposite material according to claim 1, wherein the first layer comprises a carbon-based material and wherein each first and second layer has a thickness of 1-10 times the size of a carbon atom.

5. The nanocomposite material according to claim 1, wherein the thickness of the intermediate layer is below 20 nm.

6. The nanocomposite material according to claim 1, wherein the carbon-based material comprises at least 99 atomic percent (at. %) carbon.

7. The nanocomposite material according to claim 1, wherein the salt has the following formula: ##STR00003## wherein X is any element from the periodic table that has the possibility to chelate resulting in an anionic nature; y1, y2, y3, y4 is any one of O, S, Si, C, N and P; R1, R2 are hydrocarbon chains, at least one of which is aromatic, or R1 and R2 form an aromatic ring with C1 and C2; R3, R4 are hydrocarbon chains, at least one of which is aromatic, or R3 and R4 form an aromatic ring with C3 and C4; H′ is hydrogen or a carbonyl group; wherein the combination of X, H′, y1, y2, y3, y4, R1, R2, R3, R4, C1, C2, C3 and C4 defines the anion of the salt; and A+ is any cation capable of forming a salt in combination with the anion.

8. The nanocomposite material according to claim 7, wherein not more than two H′ are a carbonyl group, and that, if two H′ are a carbonyl group, the carbonyl groups are located on C3 and C2 or on C4 and C1.

9. The nanocomposite material according to claim 7, wherein X is any of boron (B) or aluminium (Al).

10. The nanocomposite material according claim 7, wherein A is chosen from sodium (Na) and lithium (Li) and X is chosen from aluminium (Al) and boron (B).

11. A powder material comprising the nanocomposite material according to claim 1.

12. A sintered metallic product comprising a metal or metal alloy and the nanocomposite material according to claim 1.

13. The sintered metallic product according to claim 12, wherein the metal or metal alloy comprises Cu.

14. A material comprising metal powder and the nanocomposite material according to claim 1 in the form of a powder.

15. A material having a layered structure comprising the nanocomposite material according to claim 1, wherein the first layer is a substrate layer comprising a material other than said carbon-based material, the intermediate layer separates and interconnects the substrate layer and the second layer; and a plurality of layers comprising a carbon-based material on the second layer.

16. The material according to claim 15, wherein the first layer comprises a metal substrate comprising, as a main constituent, any one of the following metals, Au, Ag, Al, Cu, Fe, Ti, Ni, or a combination thereof.

17. A method of producing the nanocomposite material according to claim 1, the method comprising the steps of: preparing a first solution comprising of the carbon-based material and ethanol; preparing a second solution comprising of the salt and ethanol; adding the second solution to the first solution in a stepwise procedure; and drying the mixture of the first and second solution to evaporate solvents and thereby obtaining a powder of the nanocomposite material.

18. A nanocomposite material comprising a first layer, a second layer comprising a carbon-based material and an intermediate layer that separates and interconnects the first layer and second layer, wherein the carbon-based material comprises at least 50 atomic percent carbon, has a hexagonal lattice and has a thickness of 1-20 times the size of a carbon atom, wherein the intermediate layer comprises a salt of lithium bis(salicylato)borate [Li][BScB].

19. The nanocomposite material according to claim 18, wherein the second layer comprises graphene.

20. The nanocomposite material according to claim 18, wherein the first and second layer comprise graphene to form a graphene lithium bis(salicylato)borate (G[Li][BScB]) nanocomposite.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Different aspects and embodiments will be disclosed hereinafter with reference to the annexed drawing, in which

(2) FIG. 1 is a schematic representation of a general structure of a hybrid ionic graphene nanocomposite according to one aspect,

(3) FIG. 2 shows a first embodiment of a hybrid ionic graphene nanocomposite,

(4) FIG. 3 shows a second embodiment of a hybrid ionic graphene nanocomposite,

(5) FIG. 4 shows a third embodiment of a hybrid ionic graphene nanocomposite,

(6) FIG. 5 shows a fourth embodiment of a hybrid ionic graphene nanocomposite,

(7) FIG. 6 shows a fifth embodiment of a hybrid ionic graphene nanocomposite,

(8) FIG. 7 is a diagram showing the thermal conductivity of copper with and without a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating.

(9) FIG. 8 is a diagram showing the thermal conductivity of sintered copper with and without a lithium bis(salicylato)borate (G[Li][BScB]) additive.

(10) FIG. 9 is a diagram showing friction coefficients of uncoated Ag and Ag coated with a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating. The tribotests were performed using a CSM pin-on-disc tribometer under 2N load, 5 cm sec.sup.−1 speed and using Ag as a counter surface.

(11) FIG. 10 is a diagram showing wear coefficients of uncoated Ag and Ag coated with a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating. The tribotests were performed using a CSM pin-on-disc tribometer under 2N load, 5 cm sec−1 speed and using Ag as a counter surface.

(12) FIG. 11 is a diagram showing friction coefficients of uncoated Al and Al coated with a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating. The tribotests were performed using a CSM pin-on-disc tribometer under 2N load, 5 cm sec−1 speed and using Ag as a counter surface.

(13) FIG. 12 is a diagram showing wear coefficients of uncoated Al and Al coated with a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating. The tribotests were performed using a CSM pin-on-disc tribometer under 2N load, 5 cm sec−1 speed and using Ag as a counter surface, and

(14) FIG. 13 is a schematic representation of a piece of material according to an embodiment.

DETAILED DESCRIPTION

(15) Before the present invention is described, it is to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims and equivalents thereof.

(16) It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

(17) The terms “layered” and “multi-layered” are used to describe constructs where two or more discrete layers having the same or different composition are arranged substantially parallel on top of each other, preferably with intermediate binding layers. The terms “first”, “second” and “third” are only used to identify the layers.

(18) “Substrate” denotes any material onto which a carbon-based layer or layers is/are applied. Suitable substrates include metallic, ceramic or thermoplastic materials, and combinations thereof.

(19) The terms “metal” and “metallic” includes substantially pure metals as well as metal alloys.

(20) FIG. 1 shows a general structure of material according to the present invention, and more precisely a hybrid ionic graphene nanocomposite according to the present invention. The material shown in FIG. 1 has a layered structure comprising; a first layer 1, comprising a carbon-based material or a substrate of a material other than said carbon-based material, a second layer 2, comprising said carbon-based material, and a third, intermediate layer 3 that separates and interconnects the first and second layers 1, 2. The carbon-based material comprises at least 50 atomic percent carbon atoms, and has a hexagonal lattice, and the layer or layers 1, 2 comprising said carbon-based material preferably has/have a thickness of 1-20 times the size of a carbon atom.

(21) In FIG. 1, the first layer 1 comprises said carbon-based material. Furthermore, in the material shown in FIG. 1, the intermediate layer 3 is a layer consisting of a salt in which one of its ions, here the anion, comprises at least two separate cyclic, planar groups R1, R2, R3, R4 that are capable of forming π-π-stacking interactions with the materials of the first and second layers 1, 2. The third, intermediate layer 3 is connected to the first and second layers by π-π-stacking interaction caused by said cyclic planar groups R1, R2, R3, R4 of the salt ions.

(22) The salt of the third layer has been obtained by means of the following general synthesis protocol:

(23) ##STR00002##

(24) The constituents of the salt ions are as follows:

(25) X— is any element from the periodic table that has the possibility to chelate resulting in an anionic nature,

(26) y1, y2, y3, y4 is any one of O, S, Si, C, N and P,

(27) R1, R2 are hydrocarbon chains, at least one of which is preferably aromatic,

(28) R3, R4 are hydrocarbon chains, at least one of which is preferably aromatic,

(29) R1 and R2 form an aromatic ring with C1 and C2,

(30) R3 and R4 form an aromatic ring with C3 and C4,

(31) H is hydrogen or a carbonyl group,

(32) wherein the combination of X, H, y1, y2, y3, y4, R1, R2, R3, R4, C1, C2, C3 and C4 defines the anion of the salt, and

(33) A+ is any cation capable of forming a salt in combination with the anion.

(34) In a preferred embodiment, the salt is solid at room temperature e.g. lithium bis(salicylato)borate [Li][BScB].

(35) FIG. 2 shows a first embodiment of the material according to the invention, in which the first layer 1 is formed by a graphene layer, having a thickness in the range of 1-10 times the size of a carbon atom, and the second layer 2 is formed by a graphene layer, having a thickness in the range of 1-10 times the size of a carbon atom. R1 forms a cyclic planar ring together with C1 that forms a π-π-stacking interaction with the material of the second layer 2. R2 forms a cyclic planar ring together with C2 that forms a π-π-stacking interaction with the material of the first layer 1. R3 forms a cyclic planar ring together with C3 that forms a π-π-stacking interaction with the material of the second layer 2. R4 forms a cyclic planar ring together with C4 that forms a π-π-stacking interaction with the material of the first layer 1. In a preferred embodiment, each cyclic planar ring formed by R1, R2, R3 and R4 is an aromatic ring.

(36) Accordingly, in this embodiment the salt ion comprises four aromatic groups capable of forming a π-π-stacking interaction with the material of the first and second layers 1, 2. One or more ions of the ions of the salt bridges the distance between the first and second layers and at least one of the ions of the salt extends across the distance between the first and second layer.

(37) FIG. 3 shows a second embodiment, in which R1 forms a cyclic planar ring that forms a π-π-stacking interaction with the material of the second layer 2, and R4 forms a cyclic planar ring together with C4 that forms a π-π-stacking interaction with the material of the first layer 1. Preferably, the cyclic planar rings are benzene rings.

(38) FIG. 4 shows a third embodiment, in which cyclic planar rings of a first ionic compound of the ionic separating layer 3 forms a π-π-stacking interaction with the material of the first layer 1, and cyclic planar rings of a second ionic compound in the separation layer 3 interconnected through different interactions such as ionic, hydrogen bonding and van de Waals interactions with said first ionic compound in the layer, forms a π-π-stacking interaction with the material of the second layer 2. Preferably, the cyclic planar rings are benzene rings.

(39) FIG. 5 shows a fourth embodiment in which R1 and R2 forms a cyclic planar ring together with C1 and C2, wherein said cyclic planar ring forms π-π-stacking interaction with both the material of the first layer 1 and the material of the second layer 2. R3 and R4 do not form cyclic planar rings capable of forming π-π-stacking interaction with the materials of the first layer 1 and the second layer 2. Preferably, the cyclic planar ring is a benzene ring.

(40) FIG. 6 shows a fifth embodiment, in which R1 and R2 forms a first cyclic planar ring together with C1 and C2, wherein said first cyclic planar ring forms π-π-stacking interaction with both the material of the first layer 1 and the material of the second layer 2, and R3 and R4 forms a second cyclic planar ring together with C3 and C4, wherein said second cyclic planar ring forms π-π-stacking interaction with both the material of the first layer 1 and the material of the second layer 2. Preferably, said first and second cyclic planar rings are benzene rings.

EXAMPLES

(41) In the following examples the following synthesis were used for preparing a graphene lithium bis(salicylato)borate (G[Li][BScB]) hybrid nanocomposite. This constitutes an illustrative example of composites falling under the scope of the present disclosure.

Synthesis of Lithium Bis(Salicylato)borate ([Li][BScB]) Salt

(42) [Li][BScB] was synthesized by adding salicylic acid (24.86 g, 180 mmol) to an aqueous solution of anhydrous lithium carbonate (3.32 g, 45 mmol) and boric acid (5.56 g, 90 mmol) in 100 mL distilled water (all reagents were synthesis grade, from Sigma Aldrich). The solution was stirred for one hour at 60° C. A clear solution of [Li][BScB] salt was obtained and cooled down to room temperature. After rotary evaporation of water, the [Li][BScB] salt was washed with acetonitrile followed by filtration and drying to remove traces of unreacted reagents. The [Li][BScB] salt was purified at a yield of ca. 95%.

Synthesis of Graphene Lithium Bis(Salicylato)borate (G[Li][BScB]) Composite

(43) A 50/50 water ethanol solution containing graphene in a concentration of 50 mg/ml was prepared, stirred and ultra-sonicated for 30 min at room temperature. Another 50/50 water ethanol solution of ([Li][BScB]) with a concentration of 50 mg/ml was prepared. The graphene-containing solution was added dropwise to the salt solution under stirring at room temperature. Stirring continued for 1 hour after the complete addition of the graphene solution. After that, the solvents were rotary evaporated and a powder of a graphene lithium bis(Salicylato)borate (G[Li][BScB]) composite was obtained. The powder was dried under vacuum for 12 hours at 60° C.

(44) SEM measurements were carried out on a cross section of the thus produced G[Li][BScB] films using a scanning electron microscope. The results showed that the thickness of the graphene layer was approximately 2-3 nm while the ionic layer had a slightly higher thickness of approximately 5 nm. The theoretical thickness of a single graphene layer is 0.345 nm. This means that a graphene layer in the composite with a thickness of approximately 3 nm contains approximately 9 single layers of graphene.

(45) FIG. 13 is a schematic representation of a piece of material according to one embodiment of the present invention, wherein the piece of material comprises a metallic alloy forming a substrate (first layer) 1 and a stack of second layers 2 and third layers 3 as defined in this disclosure arranged onto a surface of the substrate 1. Some of the test specimens used in the following examples to be presented had the principle design shown in FIG. 3.

Example 1

(46) The thermal measurements were carried out using a Hot Disk® instrument (Hot Disk AB, Gothenburg, Sweden) with a custom-made cell and thermal conductivity sensor. The sensor was placed between two substrates that were coated with approximately 3 μm graphene lithium bis(salicylato)borate (G[Li][BScB]).

(47) The substrates were made of 99.99% pure Cu and had a circular shape with a diameter of 12 mm, a thickness of approximately 1 mm and a surface roughness of 100-200 nm. Uncoated substrates were tested as a reference. Three measurements were performed and the average values with standard deviations are presented for different temperatures.

(48) The results are presented in the diagram shown in FIG. 7. As can be seen, the thermal conductivity of the substrate coated with the (G[Li][BScB]) coating is remarkably higher than for the Cu reference samples, and the difference increases with increasing temperature. These results indicate the effects of the (G[Li][BScB]) coating on improving the thermal conductivity of pure Cu.

Example 2

(49) Four samples of sintered pure Cu and were prepared by powder metallurgy as follows: Cu nanoparticles (average size of 200 nm) were washed three times with ethanol and dried under vacuum for 12 h at 120° C. to ensure the removal of impurities from the powder. After drying, the Cu powder was pressed under 600 MPa and sintered at 300° C. for 12 h under Ar atmosphere. Circular samples were prepared with a dimension of 12 mm, a thickness of approximately 1 mm, and a density of 95% of the theoretical density.

(50) Additionally, four samples of sintered Cu containing 1 wt % of (G[Li][BScB]) were also prepared using the same powder metallurgy approach as above.

(51) According to another aspect, there is a provided method of producing a metal-ionic graphene nanocomposite. The method comprises the addition of ionic graphene additive at the desired concentration to a suspension containing the metal nanoparticles (ethanol and Cu nanoparticles in this particular example). The method also comprises simultaneous stirring for the mixture at room temperature for at least 30 min.

(52) The method also comprises evaporating the solvent (ethanol in this particular example) to obtain a metal-(G[Li][BScB]) powder. Solvent evaporation is followed by drying at temperature approximately 80° C. under vacuum to ensure the removal of solvent traces. After drying, the samples were prepared by pressing under 600 MPa followed by sintering at 300° C. for 12 h under Ar atmosphere. The samples are circular with dimensions of 12 mm and thickness of approximately 1 mm and a density of approximately 93% of the theoretical density. The layered structure of the (G[Li][BScB]) additive was maintained after the sintering process. The same protocol, applied in Example 1 for measuring the thermal properties, was applied here as well. The sensor was placed between two sintered discs and two measurements were performed at each temperature. The average value is calculated and the standard deviation is presented.

(53) As can be seen in FIG. 8, the thermal conductivity of the samples provided with the (G[Li][BScB]) additive is remarkably higher than for the comparison samples, and the difference increases with increasing measuring temperature. The results indicate the effect of the (G[Li][BScB]) additive on improving the thermal properties of a Cu matrix.

Example 3

(54) Samples comprising a silver substrate coated with a graphene Lithium Bis(salicylato)borate (G[Li][BScB]) were prepared as follows:

(55) The substrate was made of 99.99% pure Ag and had a square shape with the dimensions 5×5 cm, a thickness of approximately 5 mm and a surface roughness of approximately 300 nm. An uncoated Ag substrate was tested as a reference. The coating was applied by dropwise adding an ethanol suspension containing 5 mg/ml (G[Li][BScB]) on the Ag substrate. After evaporating the EtOH, the coating was annealed at 80° C. for 2 h under Ar atmosphere.

(56) The tribotests were performed using a CSM pin-on-disc tribometer under 2N load, 5 cm sec−1 speed and using pure Ag as a counter surface. Wear measurements were conducted by a tip cantilever profilometer.

(57) The results are presented in the diagram shown in FIG. 9. As can be seen, the friction coefficient of the Ag-(G[Li][BScB])-on-Ag contact pair is remarkably lower than for the Ag—Ag contact pair. Further, as can be seen in FIG. 10, the wear coefficient of the Ag-(G[Li][BScB])-on-Ag contact pair is also remarkably lower than for the Ag—Ag contact pair.

Example 4

(58) Samples comprising an aluminium substrate coated with a graphene lithium bis(salicylato)borate (G[Li][BScB]) coating were prepared and tested in the same way as in Example 3.

(59) The results are presented in the diagram shown in FIG. 11. As can be seen, the friction coefficient of the Ag-(G[Li][BScB])-on-Al is remarkably lower than that for Ag—Al contact pair. Further, as can be seen in FIG. 12, the wear coefficient of the Ag-(G[Li][BScB])-on-Al pair is remarkably lower than for the Ag—Al contact pair. This is an important advantage of the coating, and it shows that desirable properties of the multi-layered coating are indeed achieved.

(60) Without further elaboration, it is believed that a person skilled in the art can, using the present description including the examples, utilize the present invention to its fullest extent. Also, although the invention has been described herein with regard to its preferred embodiments, which constitute the best mode presently known to the inventors, it should be understood that various changes and modifications as would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention which is set forth in the claims appended hereto.

(61) Thus, while various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.