Granted Patent B2

US 12,580,176 · App. 17/136,329 · Granted Mar 17, 2026

Inventors: Michael W. Stowell (Sunnyvale, CA); Bryce H. Anzelmo (Mountain View, CA); David Tanner (Yuba City, CA); Bruce Lanning (Littleton, CO); Joe Griffith Cruz (San Jose, CA)

Assignee: Lyten, Inc.

H01M4/1393C01B32/182H01M4/0404H01M4/0421H01M4/366H01M4/38H01M4/625B82Y30/00H01M2004/021

Abstract

Claims (26)

1 . A method of manufacturing a structured composite material, the method comprising:

providing a porous graphene-based media;

conformally depositing an electrically conductive material coating on the porous graphene-based media, wherein the electrically conductive material includes one or more of carbon allotropes, carbon alloys, semiconductors, or metals;

depositing an active material on the electrically conductive material coating; and

fusing the active material, the electrically conductive material coating, and the porous graphene-based media together to form the structured composite material.

2 . The method of claim 1 , wherein the porous graphene-based media is at least partially formed of silicon.

3 . The method of claim 1 , wherein the active material comprises sulfur, sulfur compounds, silicon, silicon compounds, boron, bromine, platinum, nickel, silver, molybdenum, iron, or any combination thereof.

4 . The method of claim 1 , wherein the active material is configured to form an alloy with the porous graphene-based media.

5 . The method of claim 1 , wherein the graphene-based media is defined by a morphological structure comprising a plurality of nanometer-scale pores interspersed within a web.

6 . The method of claim 1 , wherein the porous graphene-based media is defined by a mesoporous structure with a bi-modal pore size distribution.

7 . The method of claim 1 , further comprising:

prior to depositing the electrically conductive material coating on the porous graphene-based media, pre-treating the porous graphene-based media using a chemical etch or a mechanical size reduction process.

8 . The method of claim 1 , wherein the porous graphene-based media comprises a plurality of carbon nanoparticles each having a diameter less than approximately 10 microns.

9 . The method of claim 8 , further comprising:

providing a process input material;

applying microwave or thermal energy to the process input material;

separating the process input material into one or more separated components based on the applied microwave or thermal energy; and

forming the plurality of carbon nanoparticles based on at least some of the one or more separated components.

10 . The method of claim 9 , wherein the process input material comprises carbon.

11 . The method of claim 1 , further comprising encapsulating the porous graphene-based media with a polymeric material.

12 . The method of claim 1 , wherein the porous graphene-based media has a surface area greater than approximately 50 m 2 /g.

13 . The method of claim 1 , wherein the porous graphene-based media has an electrical conductivity of greater than approximately 500 S/m.

14 . The method of claim 1 , wherein each pore in the porous graphene-based media has a dimension of less than approximately 50 nanometers (nm).

15 . The method of claim 1 , wherein the structured composite material is configured to produce elastomer compounds.

16 . The method of claim 1 , wherein the structured composite material comprises a reinforcing filler material.

17 . The method of claim 1 , wherein the structured composite material comprises a battery electrode.

Assignments (1)

Continuity (4)

References Cited (140)