Development and Scale-up of Cost-Effective Copper-Graphene Materials
Using In-Situ Synthesis and Fluidized Bed Process Systems
Abstract
The integration of copper-graphene materials has garnered significant attention due to
their exceptional mechanical, electrical, and thermal properties. The development of a cost-
effective, scalable synthesis process is critical for industrial applications. This report
explores the in-situ synthesis of copper-graphene composites using fluidized bed process
systems at Technology Readiness Level (TRL) 5.
1. Introduction
Significance of Copper-Graphene Composites:
- High thermal and electrical conductivity.
- Exceptional mechanical strength.
- Applications in electronics, energy systems, and aerospace.
Objective of the Study:
- To achieve cost-effective synthesis and coating of copper-graphene composites.
- To validate the technology in a relevant industrial setting.
2. Technology Overview
2.1 In-Situ Synthesis
- Chemical Vapor Deposition (CVD).
- Catalytic growth of graphene on copper substrates.
- Benefits of in-situ processes: improved adhesion, reduced contamination.
2.2 Fluidized Bed Process Systems
- Uniform coating of graphene layers on copper powders.
- High throughput and scalability.
- Advantages: cost efficiency, consistent product quality.
3. Methodology
Materials: Copper powder as a substrate; methane or other carbon sources for graphene.
Process Steps:
- Pre-treatment of copper particles.
- Graphene growth in a fluidized reactor.
- Post-processing for densification and quality assurance.
4. Results and Discussion
Material Properties:
- Electrical Conductivity: ≥ 110% IACS.
- Mechanical Strength: Improved by 30-50% compared to pure copper.
Challenges:
- Uniform graphene dispersion.
- Avoiding agglomeration of copper particles.
Scale-Up Feasibility:
- Process optimization for large-scale production.
- Energy and cost analysis.
5. Industrial Applications
- Electric motors and generators.
- High-frequency circuit boards.
- Thermal management systems.
6. Conclusion and Future Work
This report highlights the progress and challenges in developing copper-graphene
composites using in-situ synthesis and fluidized bed processes. Future research should
focus on optimizing the scale-up process, improving graphene dispersion, and validating the
material in industrial applications.
