To progress from the laboratory to commercial applications, it will be necessary to develop industrially scalable methods to produce large quantities of defect-free graphene. Here we show that high-shear mixing of graphite in suitable stabilizing liquids results in large-scale exfoliation to give dispersions of graphene nanosheets. X-ray photoelectron spectroscopy and Raman spectroscopy show the exfoliated flakes to be unoxidized and free of basal-plane defects. We have developed a simple model that shows exfoliation to occur once the local shear rate exceeds 10(4) s(-1). By fully characterizing the scaling behaviour of the graphene production rate, we show that exfoliation can be achieved in liquid volumes from hundreds of millilitres up to hundreds of litres and beyond. The graphene produced by this method performs well in applications from composites to conductive coatings. This method can be applied to exfoliate BN, MoS2 and a range of other layered crystals.

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Scalable production of large quantities of defect-free few-layer graphene by shear exfoliation in liquids

Mass production and commercial availability are prerequisites for the viability and wide application of graphene. The exfoliation of graphite to give graphene is one of the most promising ways to achieve large-scale production at an extremely low cost. This review focuses on discussing different exfoliation techniques based on a common mechanical mechanism; because a deep understanding of the exfoliation mechanism can provide fruitful information on how to efficiently achieve high-quality graphene by optimizing exfoliation techniques. We highlight the recent progress on mechanical exfoliation for graphene production during the last decade. The emphasis is set on the widely used sonication method with the latest insight into sonication-induced defects, the newly explored ball milling method, the fluid dynamics method that has emerged in the last three years, and the innovative supercritical fluid method. We also give an outlook on how to achieve high-quality graphene efficiently using mechanical exfoliation techniques. We hope this review will point towards a rational direction for the scalable production of graphene.

A review on mechanical exfoliation for the scalable production of graphene

Liquid phase exfoliation has become an important method for the production of large quantities of two-dimensional (2D) nanosheets. This method is versatile, having been used to produce dozens of different 2D materials in a range of stabilizing liquids. The resultant liquid-suspended nanosheets have been characterized in great detail and have been processed into a number of structures for a wide range of applications. This has led to a growing number of researchers adopting this method. As a result, best practice in terms of experimental procedure has evolved rapidly over recent years. As experimental complexity has increased, it has become more and more difficult to discuss the rational behind a chosen experimental procedure in full detail using standard “Methods” sections due to the frequent use of procedures developed in related prior reports. This can make it difficult to reproduce complex procedures and acts as a barrier to new researchers entering the field. To address this shortcoming, here we descr...

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Guidelines for Exfoliation, Characterization and Processing of Layered Materials Produced by Liquid Exfoliation

The possibility to produce and process graphene, related 2D crystals, and heterostructures in the liquid phase makes them promising materials for an ever-growing class of applications as composite materials, sensors, in flexible optoelectronics, and energy storage and conversion. In particular, the ability to formulate functional inks with on-demand rheological and morphological properties, i.e., lateral size and thickness of the dispersed 2D crystals, is a step forward toward the development of industrial-scale, reliable, inexpensive printing/coating processes, a boost for the full exploitation of such nanomaterials. Here, the exfoliation strategies of graphite and other layered crystals are reviewed, along with the advances in the sorting of lateral size and thickness of the exfoliated sheets together with the formulation of functional inks and the current development of printing/coating processes of interest for the realization of 2D-crystal-based devices.

2D-Crystal-Based Functional Inks

© 2020 The Author(s). We present an overview of the main techniques for production and processing of graphene and related materials (GRMs), as well as the key characterization procedures. We adopt a 'hands-on' approach, providing practical details and procedures as derived from literature as well as from the authors' experience, in order to enable the reader to reproduce the results. Section I is devoted to 'bottom up' approaches, whereby individual constituents are pieced together into more complex structures. We consider graphene nanoribbons (GNRs) produced either by solution processing or by on-surface synthesis in ultra high vacuum (UHV), as well carbon nanomembranes (CNM). Production of a variety of GNRs with tailored band gaps and edge shapes is now possible. CNMs can be tuned in terms of porosity, crystallinity and electronic behaviour. Section II covers 'top down' techniques. These rely on breaking down of a layered precursor, in the graphene case usually natural crystals like graphite or artificially synthesized materials, such as highly oriented pyrolythic graphite, monolayers or few layers (FL) flakes. The main focus of this section is on various exfoliation techniques in a liquid media, either intercalation or liquid phase exfoliation (LPE). The choice of precursor, exfoliation method, medium as well as the control of parameters such as time or temperature are crucial. A definite choice of parameters and conditions yields a particular material with specific properties that makes it more suitable for a targeted application. We cover protocols for the graphitic precursors to graphene oxide (GO). This is an important material for a range of applications in biomedicine, energy storage, nanocomposites, etc. Hummers' and modified Hummers' methods are used to make GO that subsequently can be reduced to obtain reduced graphene oxide (RGO) with a variety of strategies. GO flakes are also employed to prepare three-dimensional (3d) low density structures, such as sponges, foams, hydro- or aerogels. The assembly of flakes into 3d structures can provide improved mechanical properties. Aerogels with a highly open structure, with interconnected hierarchical pores, can enhance the accessibility to the whole surface area, as relevant for a number of applications, such as energy storage. The main recipes to yield graphite intercalation compounds (GICs) are also discussed. GICs are suitable precursors for covalent functionalization of graphene, but can also be used for the synthesis of uncharged graphene in solution. Degradation of the molecules intercalated in GICs can be triggered by high temperature treatment or microwave irradiation, creating a gas pressure surge in graphite and exfoliation. Electrochemical exfoliation by applying a voltage in an electrolyte to a graphite electrode can be tuned by varying precursors, electrolytes and potential. Graphite electrodes can be either negatively or positively intercalated to obtain GICs that are subsequently exfoliated. We also discuss the materials that can be amenable to exfoliation, by employing a theoretical data-mining approach. The exfoliation of LMs usually results in a heterogeneous dispersion of flakes with different lateral size and thickness. This is a critical bottleneck for applications, and hinders the full exploitation of GRMs produced by solution processing. The establishment of procedures to control the morphological properties of exfoliated GRMs, which also need to be industrially scalable, is one of the key needs. Section III deals with the processing of flakes. (Ultra)centrifugation techniques have thus far been the most investigated to sort GRMs following ultrasonication, shear mixing, ball milling, microfluidization, and wet-jet milling. It allows sorting by size and thickness. Inks formulated from GRM dispersions can be printed using a number of processes, from inkjet to screen printing. Each technique has specific rheological requirements, as well as geometrical constraints. The solvent choice is critical, not only for the GRM stability, but also in terms of optimizing printing on different substrates, such as glass, Si, plastic, paper, etc, all with different surface energies. Chemical modifications of such substrates is also a key step. Sections IV-VII are devoted to the growth of GRMs on various substrates and their processing after growth to place them on the surface of choice for specific applications. The substrate for graphene growth is a key determinant of the nature and quality of the resultant film. The lattice mismatch between graphene and substrate influences the resulting crystallinity. Growth on insulators, such as SiO2, typically results in films with small crystallites, whereas growth on the close-packed surfaces of metals yields highly crystalline films. Section IV outlines the growth of graphene on SiC substrates. This satisfies the requirements for electronic applications, with well-defined graphene-substrate interface, low trapped impurities and no need for transfer. It also allows graphene structures and devices to be measured directly on the growth substrate. The flatness of the substrate results in graphene with minimal strain and ripples on large areas, allowing spectroscopies and surface science to be performed. We also discuss the surface engineering by intercalation of the resulting graphene, its integration with Si-wafers and the production of nanostructures with the desired shape, with no need for patterning. Section V deals with chemical vapour deposition (CVD) onto various transition metals and on insulators. Growth on Ni results in graphitized polycrystalline films. While the thickness of these films can be optimized by controlling the deposition parameters, such as the type of hydrocarbon precursor and temperature, it is difficult to attain single layer graphene (SLG) across large areas, owing to the simultaneous nucleation/growth and solution/precipitation mechanisms. The differing characteristics of polycrystalline Ni films facilitate the growth of graphitic layers at different rates, resulting in regions with differing numbers of graphitic layers. High-quality films can be grown on Cu. Cu is available in a variety of shapes and forms, such as foils, bulks, foams, thin films on other materials and powders, making it attractive for industrial production of large area graphene films. The push to use CVD graphene in applications has also triggered a research line for the direct growth on insulators. The quality of the resulting films is lower than possible to date on metals, but enough, in terms of transmittance and resistivity, for many applications as described in section V. Transfer technologies are the focus of section VI. CVD synthesis of graphene on metals and bottom up molecular approaches require SLG to be transferred to the final target substrates. To have technological impact, the advances in production of high-quality large-area CVD graphene must be commensurate with those on transfer and placement on the final substrates. This is a prerequisite for most applications, such as touch panels, anticorrosion coatings, transparent electrodes and gas sensors etc. New strategies have improved the transferred graphene quality, making CVD graphene a feasible option for CMOS foundries. Methods based on complete etching of the metal substrate in suitable etchants, typically iron chloride, ammonium persulfate, or hydrogen chloride although reliable, are time- and resourceconsuming, with damage to graphene and production of metal and etchant residues. Electrochemical delamination in a low-concentration aqueous solution is an alternative. In this case metallic substrates can be reused. Dry transfer is less detrimental for the SLG quality, enabling a deterministic transfer. There is a large range of layered materials (LMs) beyond graphite. Only few of them have been already exfoliated and fully characterized. Section VII deals with the growth of some of these materials. Amongst them, h-BN, transition metal tri- and di-chalcogenides are of paramount importance. The growth of h-BN is at present considered essential for the development of graphene in (opto) electronic applications, as h-BN is ideal as capping layer or substrate. The interesting optical and electronic properties of TMDs also require the development of scalable methods for their production. Large scale growth using chemical/physical vapour deposition or thermal assisted conversion has been thus far limited to a small set, such as h-BN or some TMDs. Heterostructures could also be directly grown.

Production and processing of graphene and related materials

Scalable production of graphene sheets by mechanical delamination

A method of producing from particles of a layered material platelets comprising the layered material, the method comprising the steps of: mixing the particles of the layered material in a liquid medium; and exposing said mixed-in particles to a mechanical grinding treatment, thereby exfoliating at least some of the particles of the layered material to produce platelets from the layered material. Moreover, a method of producing from particles of a layered material platelets comprising the layered material, wherein the particles are exposed to a mechanical grinding treatment using grinding media, the stress energy of the grinding media SEGM being smaller than 10 μNm.

Method of producing platelets comprising a layered material

Since the discovery of stable graphene sheets by Novoselov und Geim in 2004 the one atom thick carbon material has been attracted great interest because of its outstanding physical, mechanical and chemical properties. Although there had been intensive research to find new ways in the preparation of single-layer graphene sheets in the last few years, especially the large-scale production of graphene still remains challenging. In this paper we present a new approach, which allows the high-yield production of graphene sheets in a simple stirred media milling process. Under mild milling conditions single- and multilayer graphene sheets have been successfully produced from commercial graphite powder in a liquid medium. During the delamination procedure, the graphite particles were stressed between the milling beads. Shear and compressive normal forces can lead under mild milling conditions, i.e. low stress energies, to a continuous mechanical peeling of graphene sheets from the graphite surface. By means of Atomic Force Microscopy a high yield of single- and multilayer graphene sheets was detected. A concentration of exfoliated sheets of 2 wt% starting from a 5 wt% suspension of coarse graphite particles could be determined after a milling time of only 3 h. This concentration is much higher than those, which were reached by most of the known chemical methods. Since stirred media milling can be realized as large-scale process, a high-yield and low-cost production of graphene flakes becomes possible at ambient temperature.

https://www.cambridge.org/core/services/aop-cambridge-core/content/view/S1946427400004231

Angela Berger

Papers

Scalable production of graphene sheets by mechanical delamination

Method of producing platelets comprising a layered material

Graphene Production With Stirred Media Mills