US20130309495A1 - Process of dry milling particulate materials - Google Patents

Process of dry milling particulate materials Download PDF

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US20130309495A1
US20130309495A1 US13/474,860 US201213474860A US2013309495A1 US 20130309495 A1 US20130309495 A1 US 20130309495A1 US 201213474860 A US201213474860 A US 201213474860A US 2013309495 A1 US2013309495 A1 US 2013309495A1
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composition
graphene
metal
matter
particulate
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US13/474,860
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InHwan Do
Michael Knox
Scott Murray
Robert M. Privette
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Priority to US13/474,860 priority Critical patent/US20130309495A1/en
Priority to KR1020147032292A priority patent/KR102107868B1/en
Priority to JP2015512666A priority patent/JP6618800B2/en
Priority to CN201380025858.7A priority patent/CN104582855B/en
Priority to PCT/US2013/038967 priority patent/WO2013173053A1/en
Priority to EP13790097.3A priority patent/EP2849887B1/en
Priority to TW102117000A priority patent/TWI589524B/en
Priority to US14/079,057 priority patent/US10079389B2/en
Publication of US20130309495A1 publication Critical patent/US20130309495A1/en
Priority to US15/155,158 priority patent/US10232377B2/en
Priority to JP2018071910A priority patent/JP2018134639A/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
    • B02C17/00—Disintegrating by tumbling mills, i.e. mills having a container charged with the material to be disintegrated with or without special disintegrating members such as pebbles or balls
    • B02C17/18—Details
    • B02C17/20—Disintegrating members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/6261—Milling
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/04—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of carbon-silicon compounds, carbon or silicon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
    • H01G11/22—Electrodes
    • H01G11/30—Electrodes characterised by their material
    • H01G11/46—Metal oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
    • H01G11/84—Processes for the manufacture of hybrid or EDL capacitors, or components thereof
    • H01G11/86—Processes for the manufacture of hybrid or EDL capacitors, or components thereof specially adapted for electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/362—Composites
    • H01M4/364—Composites as mixtures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
    • H01M4/386—Silicon or alloys based on silicon
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H01M4/587—Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • H01M4/622—Binders being polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
    • H01G11/22—Electrodes
    • H01G11/30—Electrodes characterised by their material
    • H01G11/32—Carbon-based
    • H01G11/36—Nanostructures, e.g. nanofibres, nanotubes or fullerenes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/13—Energy storage using capacitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]

Definitions

  • This invention deals with graphene platelet nano composites with metal or metal oxide, and graphene platelet nano coated with metal or metal oxide.
  • the coated and composited particles are useful as electrodes and for electrical applications.
  • Graphite is formed by many layers of carbon in highly structured platelets. These platelets, when separated from the graphite superstructure, are collectively called graphene. Graphene has interesting chemical, physical, and electrical properties. These properties make graphene a highly valued product. The quality of the graphene, as defined by particle diameter, particle width, and surface area, determine its industrial utility. It is advantageous to coat or composite graphene with metal particles for electrical applications.
  • Graphene produced by media ball milling has very small particle size with a relatively high surface area. It is uniquely suited to make nano-composites or coatings by coating or admixing other particles. Metals or metal oxides can be coated or formed into composites with the high surface area, relatively low aspect ratio graphene. It is believed by the inventors herein that the materials of this invention have unique aspect ratios. Ground graphite admixed with silicon has an aspect ratio fairly close to 1, graphene from a GO process, epitaxially grown graphene, or graphene from an intercalated—heating process has a very high aspect ratio. The moderate aspect ratio graphene of this invention better coats 1 to 4 micron particles and better mixes with even small nano-particles.
  • Native graphite has a very high G/D ratio.
  • Graphite ground to amorphous powder has the G/D ratio.
  • the material of the instant invention starts high and tends toward 2 the more the material is processed.
  • Amorphous graphite also has a G peak red shift to 2000 cm ⁇ 1 .
  • the material of the instant invention may have a small red shift, but from the quality of the data it is hard to determine.
  • the very high surface area and aspect ratio confirms it is largely graphene nano-platelets.
  • Mechanically exfoliated graphene is distinct from ground graphite, in that, it maintains the strong crystalline sp2 structure. As graphite is ground to amorphous, the ratio of G to D Raman lines tends to 2 and the G line red shifts from 1560 cm ⁇ 1 to 2000 cm ⁇ 1 .
  • the G peak is referred to as the graphene peak.
  • the D peak referred to as the Disorder peak. The more graphite is ground, the more the G peak is reduced and the D peak is increased.
  • the added particles are larger than the graphene, they are coated with graphene, and if they are about the same approximate size, a nano-composite forms.
  • the nanocomposites are useful for producing electrodes, especially for battery and capacitor applications.
  • FIG. 1 is a graph of battery performance of a Si/graphene (200-250 m 2 /g, 100 minutes processing time).
  • the exfoliated material has a particle size of 10 microns by 5 nm thick, or less.
  • the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
  • a second embodiment that is a process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a particulate material selected from the group consisting of i. ceramic, ii. glass, and iii. quartz, to obtain a composition wherein the layered material is exfoliated and wherein the particulate material is coated with the exfoliated material.
  • the exfoliated material has a particle size of 500 nanometers or less.
  • the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
  • a fourth embodiment there is a composited product obtained by the first embodiment and a coated product obtained by the second embodiment.
  • the graphene produced by the methods of this invention has a relatively narrow aspect ratio, greater than graphite.
  • aspect ratios above 5 and below 200 are preferred and more preferred are aspect ratios above 10 and below 25.
  • the small that is, 1 to 5 nanometers thick, and 50 to 100 nanometers diameter, high surface area (above 500 BET), medium aspect ratio graphene, is a unique size for coating with small metal or metal oxide particles.
  • the metals useful in this invention are the metalloid silicon, and the metals tin, iron, magnesium, manganese, aluminum, lead, gold, silver, titanium, platinum, palladium, ruthenium, copper, nickel, rhodium, and alloys of any of the above.
  • the plastic milling media useful in this invention has a hardness on the Brinell Scale in the range of 3 to 100.
  • the plastic milling media is selected from the group consisting essentially of polyacetals, polyacrylates, such as, for example, methylmethacrylate, polycarbonate, polystyrene, poly-propylene, polyethylene, polytetrafluoroethylene, polyethylene-imide, polyvinylchloride, polyamine-imide, phenolics and formaldehyde-based thermosetting resins, and alloys of any of the plastics named.
  • the particulate metal oxides useful in this invention are metal oxides selected from silicon, tin, iron, magnesium, manganese, aluminum, lead, gold, silver, titanium, platinum, palladium, ruthenium, copper, nickel, rhodium, tungsten, cobalt, molybdenum, and alloys of any the above named metal oxides, wherein the metal and metal oxide particles have a size of 100 microns or less. Preferred are particle sizes of 10 microns or less, and most preferred are particle sizes of 5 microns or less.
  • Metal carbides, metal nitrides are useful in this invention, as well as non-layered materials.
  • Graphene useful in this invention is preferred to have a thickness of 5 nm or less.
  • the polymethylmeth-acrylate balls can be replaced with polycarbonate, polystyrene, polypropylene, polyethylene, polytetrafluoroethylene, polyethyleneimide, polyvinylchloride and polyamide-imide to control milling efficiency, graphene size, porosity distribution and surface area at a fixed milling time, contact quality between Si and graphene surface.
  • the surface area of the Si/graphene composite produced can be varied from 100 m 2 /g to 700 m 2 /g depending on milling time (60 to 500 min.) and Si/graphene composition and type of ball materials.
  • the result for the battery performance of a Si/graphene (200 to 250 m 2 /g, 100 min. processing) sample as an anode for a lithium ion battery is plotted infra.
  • the Si/graphene shows high capacity (>800 mAh/g, electrode loading) over 35 cycles at 100 mA/g, which supports the low cost, simple, time-saving, environmentally benign, flexible way to produce high performance graphene-based composite materials for energy applications. Some fluctuation of the capacity is due to the variation of temperature.

Abstract

Graphene produced by media ball milling has very small particle size, a relatively high surface area and unique aspect ratios. It is uniquely suited to make nano-composites or coating by coating or admixing other particles. Metals or metal oxides can be coated or formed into composites with the high surface area, relatively low aspect ratio graphene. If the added particles are larger than the graphene, they are coated with graphene, and if they are about the same approximate size, a nano-composite forms. The nanocomposites are useful for producing electrodes, especially for battery and supercapacitor applications.

Description

    BACKGROUND OF THE INVENTION
  • This invention deals with graphene platelet nano composites with metal or metal oxide, and graphene platelet nano coated with metal or metal oxide. The coated and composited particles are useful as electrodes and for electrical applications.
  • Graphite is formed by many layers of carbon in highly structured platelets. These platelets, when separated from the graphite superstructure, are collectively called graphene. Graphene has interesting chemical, physical, and electrical properties. These properties make graphene a highly valued product. The quality of the graphene, as defined by particle diameter, particle width, and surface area, determine its industrial utility. It is advantageous to coat or composite graphene with metal particles for electrical applications.
  • Xg Sciences, Inc. headquartered in Lansing, Mich. produces a “C” grade graphene by a high energy, plastic media, dry, mechanical milling process. Grade size characteristics make it uniquely suited to coating or mixing with nanoparticles to form useful materials for electrodes.
  • The applicant is aware of U.S. Patent publication 2011/0111303 A1 that published on May 12, 2011 as showing a wet process for treating graphene with silicon.
  • Also, the patentees are aware of EP2275385 in the name of Peukert, et al in which a wet process is set forth for grinding particulate materials, wherein the grinding media is yttrium stabilized zirconia.
    • SUMMARY OF THE INVENTION
  • Graphene produced by media ball milling has very small particle size with a relatively high surface area. It is uniquely suited to make nano-composites or coatings by coating or admixing other particles. Metals or metal oxides can be coated or formed into composites with the high surface area, relatively low aspect ratio graphene. It is believed by the inventors herein that the materials of this invention have unique aspect ratios. Ground graphite admixed with silicon has an aspect ratio fairly close to 1, graphene from a GO process, epitaxially grown graphene, or graphene from an intercalated—heating process has a very high aspect ratio. The moderate aspect ratio graphene of this invention better coats 1 to 4 micron particles and better mixes with even small nano-particles.
  • Based on Raman spectroscopy with the aspect ratio, particle size, and/or surface area, provides graphene in this invention that is unique.
  • Based on the following table calculated from Raman Spectroscopy and measuring peak height, generated the following table.
  • m2/g G D G/D Gpeak
    250 50 5 10 1580
    400 19 6 3.2
    500 21 7 3
    600 16 6 2.7 1585
  • Native graphite has a very high G/D ratio. Graphite ground to amorphous powder has the G/D ratio. the material of the instant invention starts high and tends toward 2 the more the material is processed. Amorphous graphite also has a G peak red shift to 2000 cm−1. The material of the instant invention may have a small red shift, but from the quality of the data it is hard to determine. The very high surface area and aspect ratio confirms it is largely graphene nano-platelets.
  • Mechanically exfoliated graphene is distinct from ground graphite, in that, it maintains the strong crystalline sp2 structure. As graphite is ground to amorphous, the ratio of G to D Raman lines tends to 2 and the G line red shifts from 1560 cm−1 to 2000 cm−1. The G peak is referred to as the graphene peak. The D peak referred to as the Disorder peak. The more graphite is ground, the more the G peak is reduced and the D peak is increased.
  • If the added particles are larger than the graphene, they are coated with graphene, and if they are about the same approximate size, a nano-composite forms. The nanocomposites are useful for producing electrodes, especially for battery and capacitor applications.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a graph of battery performance of a Si/graphene (200-250 m2/g, 100 minutes processing time).
    •  THE INVENTION
  • Thus, in one embodiment, there is a process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a non-layered material, to obtain a composition wherein the layered material is exfoliated and wherein the non-layered material is composited with the exfoliated material.
  • The exfoliated material has a particle size of 10 microns by 5 nm thick, or less. In addition, the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
  • In a second embodiment, that is a process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a particulate material selected from the group consisting of i. ceramic, ii. glass, and iii. quartz, to obtain a composition wherein the layered material is exfoliated and wherein the particulate material is coated with the exfoliated material.
  • The exfoliated material has a particle size of 500 nanometers or less. In addition, the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
  • In, a fourth embodiment, there is a composited product obtained by the first embodiment and a coated product obtained by the second embodiment.
    • DETAILED DESCRIPTION OF THE INVENTION
  • The graphene produced by the methods of this invention has a relatively narrow aspect ratio, greater than graphite. For this invention aspect ratios above 5 and below 200 are preferred and more preferred are aspect ratios above 10 and below 25.
  • The small, that is, 1 to 5 nanometers thick, and 50 to 100 nanometers diameter, high surface area (above 500 BET), medium aspect ratio graphene, is a unique size for coating with small metal or metal oxide particles.
  • The metals useful in this invention are the metalloid silicon, and the metals tin, iron, magnesium, manganese, aluminum, lead, gold, silver, titanium, platinum, palladium, ruthenium, copper, nickel, rhodium, and alloys of any of the above.
  • The plastic milling media useful in this invention has a hardness on the Brinell Scale in the range of 3 to 100. The plastic milling media is selected from the group consisting essentially of polyacetals, polyacrylates, such as, for example, methylmethacrylate, polycarbonate, polystyrene, poly-propylene, polyethylene, polytetrafluoroethylene, polyethylene-imide, polyvinylchloride, polyamine-imide, phenolics and formaldehyde-based thermosetting resins, and alloys of any of the plastics named.
  • The particulate metal oxides useful in this invention are metal oxides selected from silicon, tin, iron, magnesium, manganese, aluminum, lead, gold, silver, titanium, platinum, palladium, ruthenium, copper, nickel, rhodium, tungsten, cobalt, molybdenum, and alloys of any the above named metal oxides, wherein the metal and metal oxide particles have a size of 100 microns or less. Preferred are particle sizes of 10 microns or less, and most preferred are particle sizes of 5 microns or less.
  • Metal carbides, metal nitrides are useful in this invention, as well as non-layered materials.
  • Graphene useful in this invention is preferred to have a thickness of 5 nm or less.
    • EXAMPLES Example 1
  • Two grams of natural graphite and 1 g of micron sized Si (1 to 4 um) were loaded into a 65 ml stainless steel grinding container and milled in the presence of 24 g of polymethyl-methacrylate balls. The polymethylmethacrylate balls consisted of two different sizes, namely, ¼ inches and ⅜ inches in diameter. The high energy milling machine was operated at <1500 rpm and its clamp speed was 1060 cycle/min. The polymethylmeth-acrylate balls can be replaced with polycarbonate, polystyrene, polypropylene, polyethylene, polytetrafluoroethylene, polyethyleneimide, polyvinylchloride and polyamide-imide to control milling efficiency, graphene size, porosity distribution and surface area at a fixed milling time, contact quality between Si and graphene surface. The surface area of the Si/graphene composite produced can be varied from 100 m2/g to 700 m2/g depending on milling time (60 to 500 min.) and Si/graphene composition and type of ball materials.
  • The result for the battery performance of a Si/graphene (200 to 250 m2/g, 100 min. processing) sample as an anode for a lithium ion battery is plotted infra. The Si/graphene shows high capacity (>800 mAh/g, electrode loading) over 35 cycles at 100 mA/g, which supports the low cost, simple, time-saving, environmentally benign, flexible way to produce high performance graphene-based composite materials for energy applications. Some fluctuation of the capacity is due to the variation of temperature.
    • Example 2
  • Two grams of natural graphite and 1 g of nano sized metal oxides (Fe2O3, NiO, CoO3, MnO3) were loaded in a 65 ml stainless steel grinding container and milled in the presence of 24 g of polymethylmethyacrylate balls. The products can be used as anode materials for lithium batteries and electrodes for supercapacitors.

Claims (41)

What is claimed is:
1. A process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a non-layered material, to obtain a composition wherein the layered material is exfoliated and wherein the non-layered material is composited with the exfoliated material, the exfoliated material having a particle size of 10 microns by 5 nm thick, or less, and wherein the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
2. The process as claimed in claim 1 wherein the non-layered material is selected from the group consisting essentially of:
i. a particulate metal and,
ii. a particulate metal oxide.
3. The process as claimed in claim 1 wherein the layered material is graphite.
4. The process as claimed in claim 1 wherein the milling media has a surface energy essentially equivalent to the surface energy of the layered material.
5. The process as claimed in claim 1 wherein the milling media has a hardness on the Brinell Scale in the range of 3 to 100.
6. The process as claimed in claim 1 wherein the exfoliated material has an aspect ratio of greater than about 25.
7. The process as claimed in claim 1 wherein the exfoliated material has an aspect ratio of from 5 to 200.
8. The process as claimed in claim 1 wherein the exfoliated material has a size in the range of from 50 nm to 10 microns.
9. The process as claimed in claim 1 wherein the exfoliated material has a thickness of from 1 nm to 5 nm.
10. The process as claimed in claim 1 wherein the milling media is plastic material.
11. The process as claimed in claim 10 wherein the plastic is selected from the group consisting essentially of:
i. polymethylmethacrylate,
ii. polycarbonate,
iii. polystyrene,
iv. polypropylene,
v. polyethylene,
vi. polytetrafluoroethylene,
vii. polyethyleneimide,
viii. polyvinylchloride,
ix. polyamine-imide, and,
x. alloys of any of i. to ix.
12. The process as claimed in claim 2 wherein the particulate metals are selected from the group consisting essentially of:
i. silicon,
ii. tin,
iii. iron,
iv. magnesium,
v. manganese,
vi. aluminum,
vii. lead,
viii. gold,
ix. silver,
x. titanium,
xi. platinum,
xii. palladium,
xiii. ruthenium,
xiv. copper,
xv. nickel,
xvi. rhodium, and,
xvii. alloys of any of i. to xvi.
13. The process as claimed in claim 2 wherein the particulate metal oxides are selected from the group consisting essentially of oxides of:
i. silicon,
ii. tin,
iii. iron,
iv. magnesium,
v. manganese,
vi. aluminum,
vii. lead,
viii. gold,
ix. silver,
x. titanium,
xi. platinum,
xii. palladium,
xiii. ruthenium,
xiv. copper,
xv. nickel,
xvi. rhodium, and,
xvii. alloys of any of i. to xvi.
14. The process as claimed in claim 1 wherein the particulate non-layered material has a size less than 100 microns.
15. The process as claimed in claim 1 wherein the particulate are metal carbides.
16. The process as claimed in claim 1 wherein the particulate materials are metal nitrides.
17. A product when produced by the process of claim 1.
18. An electrode produced from the product as claimed in claim 17.
19. A catalyst produced from the product as claimed in claim 17.
20. A coating produced from the product as claimed in claim 17.
21. An electronic component manufactured from the product as claimed in claim 17.
22. A thermally conductive component manufactured from the product as claimed in claim 17.
23. A process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a particulate material selected from the group consisting of i. ceramic, ii. glass, and iii. quartz, to obtain a composition wherein the layered material is exfoliated and wherein the particulate material is coated with the exfoliated material, the exfoliated material having a particle size of 500 nanometers or less, and wherein the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
24. A process of dry milling particulate materials, wherein at least one of the particulate materials is a layered material, in the presence of a particulate material selected from the group consisting of i. ceramic, ii. glass, and iii. quartz, to obtain a composition wherein the layered material is exfoliated and wherein the particulate material is coated with the exfoliated material, the exfoliated material having a particle size of 10 microns or more, and the wherein the dry milling is controlled by controlling the surface energy of the milling media in addition to controlling the hardness of the milling media.
25. A composition of matter comprising particles composited with graphene wherein the particles are selected from the group consisting essentially of metal particles, and metal oxide particles, wherein the metal and metal oxide particles have a size of 100 microns or smaller.
26. A composition of matter as claimed in claim 25 wherein the metal and metal oxide particles have a size of 100 microns or less.
27. A composition of matter as claimed in claim 25 wherein the metal and metal oxide particles have a size of 10 microns or less.
28. A composition of matter as claimed in claim 25 wherein the metal and metal oxide particles have a size of 1 micron or less.
29. A composition of matter as claimed in claim 25 wherein the graphene is less than 5 nm thick.
30. A composition of matter as claimed in claim 25 wherein the graphene is a monolayer thick.
31. A composition of matter as claimed in claim 25 wherein the oxygen content of the graphene is ten atomic weight percent or less.
32. A composition of matter as claimed in claim 25 wherein the metal is selected from the group consisting essentially of iron, magnesium, cobalt, molybdenum, and lead.
33. A composition of matter as claimed in claim 25 wherein the metal oxide is selected from the group of oxides consisting essentially of iron oxide, magnesium oxide, cobalt oxide, molybdenum oxide, and lead oxide.
34. A composition of matter as claimed in claim 25 wherein the size of the graphene particle is less than 5 microns.
35. A composition of matter as claimed in claim 25 wherein the surface area of the graphene is greater than about 300 m2/g BET.
36. A composition of matter as claimed in claim 25 wherein the metal particles are larger than the graphene composited with them.
37. A composition of matter as claimed in claim 25 wherein the metal particle are essentially the same size as the graphene they are combined with.
38. A composition of matter as claimed in claim 25 that is a nanocomposite.
39. An electrode manufactured from the composition of claim 25.
40. A battery comprising at least one electrode as claimed in claim 39.
41. A capacitor comprising an electrode as claimed in claim 39.
US13/474,860 2012-05-18 2012-05-18 Process of dry milling particulate materials Abandoned US20130309495A1 (en)

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US13/474,860 US20130309495A1 (en) 2012-05-18 2012-05-18 Process of dry milling particulate materials
EP13790097.3A EP2849887B1 (en) 2012-05-18 2013-05-01 Process of dry milling particulate materials
JP2015512666A JP6618800B2 (en) 2012-05-18 2013-05-01 Process for dry grinding of particulate material
CN201380025858.7A CN104582855B (en) 2012-05-18 2013-05-01 The method of dry grinding bulk material
PCT/US2013/038967 WO2013173053A1 (en) 2012-05-18 2013-05-01 Process of dry milling particulate materials
KR1020147032292A KR102107868B1 (en) 2012-05-18 2013-05-01 Process of dry milling particulate materials
TW102117000A TWI589524B (en) 2012-05-18 2013-05-14 Process of dry milling particulate materials
US14/079,057 US10079389B2 (en) 2012-05-18 2013-11-13 Silicon-graphene nanocomposites for electrochemical applications
US15/155,158 US10232377B2 (en) 2012-05-18 2016-05-16 Process of dry milling particulate materials
JP2018071910A JP2018134639A (en) 2012-05-18 2018-04-03 Process of dry-pulverizing particulate material

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