Integral 3D graphene-carbon hybrid foam
Provided is an integral 3D graphene-carbon hybrid foam composed of multiple pores and pore walls, wherein the pore walls contain single-layer or few-layer graphene sheets chemically bonded by a carbon material having a carbon material-to-graphene weight ratio from 1/100 to 1/2, wherein the few-layer graphene sheets have 2-10 layers of stacked graphene planes having an inter-plane spacing d 002 from 0.3354 nm to 0.40 nm and the graphene sheets contain a pristine graphene material having essentially zero % of non-carbon elements, or a non-pristine graphene material having 0.01% to 25% by weight of non-carbon elements wherein said non-pristine graphene is selected from graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof. Also provided are a process for producing the hybrid form, products containing the hybrid foam, and its applications.
1. An integral graphene-carbon hybrid foam comprising multiple pores and pore walls, wherein said pore walls comprise single-layer or few-layer graphene sheets selected from the group consisting of graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, and combinations thereof and containing 0.001% to 25% by weight of non-carbon elements; wherein said few-layer graphene sheets have 2-10 layers of stacked graphene planes having an inter-plane spacing d 002 from 0.3354 nm to 0.40 nm as measured by X-ray diffraction; and wherein said single-layer or few-layer graphene sheets are chemically bonded by a carbon material and have a carbon material-to-graphene weight ratio from 1/200 to 1/2.
2. The integral graphene-carbon hybrid foam of claim 1 , having a density from 0.005 to 1.7 g/cm 3 or an average pore size from 2 nm to 50 nm.
3. The integral graphene-carbon hybrid foam of claim 1 , having an oxygen content less than 1% by weight, wherein said pore walls have an inter-graphene spacing less than 0.35 nm, a thermal conductivity from 250 to 400 W/mK per unit of specific gravity, and/or an electrical conductivity no less than 2,500 to 4,000 S/cm per unit of specific gravity.
4. The integral graphene-carbon hybrid foam of claim 1 , having a thickness from 100 nm to 10 cm and a length of at least 2 meters.
5. The integral graphene-carbon hybrid foam of claim 1 , wherein said pore walls comprise stacked graphene planes having an inter-graphene spacing less than 0.337 nm and a mosaic spread value less than 1.0.
6. The integral graphene-carbon hybrid foam of claim 1 , wherein said pore walls comprise a three dimensional network of interconnected graphene planes or wherein said foam comprises mesoscaled pores having a pore size from 2 nm to 50 nm.
7. The integral graphene-carbon hybrid foam of claim 1 , wherein said pore walls further comprise a pristine graphene.
8. An integral graphene-carbon hybrid foam comprising multiple pores and pore walls, wherein said pore walls comprise single-layer or few-layer graphene sheets selected from the group consisting of doped graphene, chemically functionalized graphene, and combinations thereof and containing 0.001% to 25% by weight of non-carbon elements;
wherein said few-layer graphene sheets have 2-10 layers of stacked graphene planes having an inter-plane spacing d 002 from 0.3354 nm to 0.40 nm as measured by X-ray diffraction;
and wherein said single-layer or few-layer graphene sheets are chemically bonded by a carbon material and have a carbon material-to-graphene weight ratio from 1/200 to 1/2.
9. The integral graphene-carbon hybrid foam of claim 8 , having a density from 0.005 to 1.7 g/cm 3 or an average pore size from 2 nm to 50 nm.
10. The integral graphene-carbon hybrid foam of claim 8 , having a thickness from 100 nm to 10 cm and a length of at least 2.
11. The integral graphene-carbon hybrid foam of claim 8 , having an oxygen content less than 1% by weight, wherein said pore walls have an inter-graphene spacing less than 0.35 nm, a thermal conductivity from 250 to 400 W/mK per unit of specific gravity, and/or an electrical conductivity no less than 2,500 to 4,000 S/cm per unit of specific gravity.
12. The integral graphene-carbon hybrid foam of claim 8 , wherein said pore walls comprise stacked graphene planes having an inter-graphene spacing less than 0.337 nm and a mosaic spread value less than 1.0.
13. The integral graphene-carbon hybrid foam of claim 8 , wherein said pore walls comprise a three dimensional network of interconnected graphene planes.
14. The integral graphene-carbon hybrid foam of claim 8 , wherein said pore walls further comprise a pristine graphene.
15. An integral pristine graphene-carbon hybrid foam comprising multiple pores and pore walls, wherein said pore walls comprise single-layer or few-layer pristine graphene sheets chemically bonded by a carbon material having a carbon material-to-graphene weight ratio from 1/200 to 1/2, wherein said few-layer graphene sheets have 2-10 layers of stacked graphene planes having an inter-plane spacing d 002 from 0.3354 nm to 0.40 nm as measured by X-ray diffraction.
16. The integral pristine graphene-carbon hybrid foam of claim 15 , having a density from 0.005 to 1.7 g/cm 3 .
17. The integral pristine graphene-carbon hybrid foam of claim 15 , having an oxygen content less than 1% by weight, wherein said pore walls have an inter-graphene spacing less than 0.35 nm, a thermal conductivity from 250 to 400 W/mK per unit of specific gravity, and/or an electrical conductivity no less than 2,500 to 4,000 S/cm per unit of specific gravity.
18. The integral pristine graphene-carbon hybrid foam of claim 15 , wherein said integral pristine graphene-carbon hybrid foam comprises mesoscaled pores having a pore size from 2 nm to 50 nm.
19. The integral pristine graphene-carbon hybrid foam of claim 15 , wherein said pore walls comprise stacked graphene planes having an inter-graphene spacing less than 0.337 nm and a mosaic spread value less than 1.0.
20. The integral pristine graphene-carbon hybrid foam of claim 15 , wherein said pore walls comprise a three dimensional network of interconnected graphene planes.