WO2016101436A1 - 一种结构可控的三维石墨烯多孔材料制备方法 - Google Patents

一种结构可控的三维石墨烯多孔材料制备方法 Download PDF

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WO2016101436A1
WO2016101436A1 PCT/CN2015/075960 CN2015075960W WO2016101436A1 WO 2016101436 A1 WO2016101436 A1 WO 2016101436A1 CN 2015075960 W CN2015075960 W CN 2015075960W WO 2016101436 A1 WO2016101436 A1 WO 2016101436A1
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dimensional
graphene
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闫春泽
史玉升
朱伟
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Huazhong University of Science and Technology
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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F4/00—Processes for removing metallic material from surfaces, not provided for in group C23F1/00 or C23F3/00
    • C23F4/04—Processes for removing metallic material from surfaces, not provided for in group C23F1/00 or C23F3/00 by physical dissolution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/15—Nano-sized carbon materials
    • C01B32/182—Graphene
    • C01B32/184—Preparation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/15—Nano-sized carbon materials
    • C01B32/182—Graphene
    • C01B32/184—Preparation
    • C01B32/186—Preparation by chemical vapour deposition [CVD]
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/15—Nano-sized carbon materials
    • C01B32/182—Graphene
    • C01B32/194—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2204/00—Structure or properties of graphene
    • C01B2204/20—Graphene characterized by its properties
    • C01B2204/32—Size or surface area
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/12—Surface area
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/14—Pore volume
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2006/00—Physical properties of inorganic compounds
    • C01P2006/16—Pore diameter

Definitions

  • the invention belongs to the technical field of graphene preparation, and more particularly to a method for preparing a three-dimensional graphene porous material with controllable structure, and is particularly suitable for preparing an effective and precisely controlled three-dimensional graphene porous material by preparing an internal structure and an external shape. product.
  • Graphene is a two-dimensional crystal material composed of a single layer of carbon atoms, which not only has excellent electrical properties (electron mobility at room temperature up to 2 ⁇ 105 cm 2 /V ⁇ s), but also outstanding thermal properties (thermal conductivity) 5000W/m ⁇ K), ultra-high specific surface area (2630m 2 /g) and excellent mechanical properties (Young's modulus up to 1100GPa, breaking strength 125GPa), but also some unique features such as perfect quantum tunneling performance. Because graphene materials have so many unique and excellent properties, they have great application prospects in the fields of electronics, information, energy, materials and biomedicine.
  • CN102674321A discloses a method for depositing a graphene film on a surface of a three-dimensional foamed nickel template by chemical vapor deposition, and obtaining a porous foamy graphene after dissolving the porous metal substrate
  • CN103265022A discloses a spontaneous deposition on a conductive substrate.
  • a method of three-dimensional graphene discloses a method of preparing porous through-three-dimensional graphene using a carbonate or bicarbonate as a template, and the like.
  • the present invention provides a structure controllable method for preparing a three-dimensional graphene porous material, wherein the preparation process thereof and key processes such as the manufacture of a three-dimensional porous metal template and the growth of graphene are provided.
  • the research and design of the other links can effectively overcome the uncontrollable defects of the external shape and internal structure existing in the prior art, and have the characteristics of easy manipulation, short preparation cycle and wide adaptability, so it is especially suitable for large-scale scale. Production of high quality, versatile three-dimensional graphene porous materials.
  • a structure controllable method for preparing a three-dimensional graphene porous material characterized in that the method comprises the following steps:
  • a correspondingly shaped three-dimensional porous metal structure is prepared by an additive manufacturing technique using a metal powder under a protective atmosphere of an inert gas; wherein the metal powder used is selected from the group consisting of nickel and copper. , iron or cobalt, and having an average particle diameter of 5 ⁇ m to 50 ⁇ m, the particle shape of which is spherical or nearly spherical;
  • step (d) growing a graphene film on the metal template obtained in the step (c) by chemical vapor deposition: in the process, first, the metal template is placed in a tube furnace and heated in a mixed atmosphere of inert gas and hydrogen. After heating to 800 ° C to 1000 ° C for 0.5 hour to 1 hour, the carbon source is introduced to continue the reaction, and then cooled to room temperature under a protective atmosphere of an inert gas, thereby producing a raw Three-dimensional graphene grown on the metal template;
  • step (e) arranging an etching solution having a molar concentration of 1 mol/L to 3 mol/L, and immersing the product obtained in the step (d) therein, and refluxing at a temperature of 60 ° C to 90 ° C until the metal template is completely dissolved. And then, after washing and drying, a three-dimensional graphene porous material product is obtained, and the three-dimensional graphene porous material product includes internal structural parameters including pore size, porosity and pore shape, and external shapes thereof are in step (a)
  • the CAD model built is consistent.
  • the CAD model exhibits an ordered periodic porous structure or a randomly arranged interconnected three-dimensional porous structure, and has a unit size of between 0.5 mm and 10 mm.
  • the additive manufacturing technique includes selective laser melting, direct metal laser sintering, or electron beam melting, and the average particle diameter of the metal powder is further controlled to be 10 ⁇ m to 30 ⁇ m.
  • the obtained three-dimensional porous metal structure is heated to 1200 ° C to 1370 ° C under a protective atmosphere of argon gas for about 12 hours, and then cooled to room temperature.
  • the carbon source is selected from the group consisting of styrene, methane or ethane, and the flow rate thereof is controlled to be 0.2 mL/h to 200 mL/h, and the reaction time after the introduction is 0.5 hour. ⁇ 3 hours.
  • the inert gas is argon gas
  • the volume ratio thereof to hydrogen gas is 1:1 to 3:1, and for a mixed atmosphere of argon gas and hydrogen gas
  • the flow rate of argon gas was controlled to be 100 mL/min to 200 mL/min
  • the flow rate of hydrogen gas was controlled to be 180 mL/min to 250 mL/min.
  • the etching solution is selected from one or a mixture of the following: hydrochloric acid, sulfuric acid, nitric acid, and ferric chloride.
  • the preparation method according to the invention has the advantages of wide source of raw materials, environmental protection, low cost and low energy consumption, and has the characteristics of convenient manipulation, short preparation cycle, high yield and high degree of design freedom, and thus is especially suitable for mass production and high quality. Multi-functional three-dimensional graphene porous product with advanced structure.
  • Figure 1 is a process flow diagram of a method of preparing a three-dimensional graphene porous material in accordance with the present invention.
  • CAD software is used to establish a three-dimensional porous unit body having a cell size of 0.5 mm, wherein the unit body array is designed as a periodic porous structure having a porosity of 50% and an ordered arrangement.
  • a pure nickel powder having a particle size distribution in the range of 5 to 20 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and the laser power was set to 200 W, the scanning speed was 500 mm/s, the layer thickness was 0.01 mm, and the scanning pitch was 0.08 mm.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by a selective laser melting (SLM) technique.
  • SLM selective laser melting
  • porous metal nickel structure was placed in a 1370 degree tube furnace, and heat treatment was performed for 10 hours under Ar gas protection.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (180 mL / min) and H 2 (200 mL / min); after holding for 30 minutes, the quartz was applied to the quartz. Styrene (0.254 mL/h) was passed through the tube for 1 h; finally, H 2 was turned off, and cooled to room temperature under Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template in which graphene was grown was immersed in a hydrochloric acid solution having a concentration of 3 mol/L, and refluxed at 80 ° C until the three-dimensional porous metal template was completely dissolved, and then washed and dried to obtain a three-dimensional graphene porous structure.
  • the test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.
  • CAD software is used to establish a three-dimensional porous unit body with a cell size of 1 mm, wherein the unit body array is designed as a periodic porous structure with a porosity of 75% and an ordered arrangement.
  • a pure nickel powder having a particle size distribution in the range of 30 to 50 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and the laser power was set to 250 W, the scanning speed was 700 mm/s, the layer thickness was 0.02 mm, and the scanning pitch was 0.08 mm.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by direct metal laser sintering (DMLS) under the protection of argon.
  • DMLS direct metal laser sintering
  • porous metal nickel structure was placed in a 1370 degree tube furnace, and heat treatment was performed for 12 hours under Ar gas protection.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (180 mL / min) and H 2 (200 mL / min); after holding for 45 minutes, the quartz was applied to the quartz. Styrene (0.508 mL/h) was introduced into the tube and reacted for 0.5 h. Finally, H 2 was turned off, and cooled to room temperature in an Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template in which graphene was grown was immersed in a hydrochloric acid solution having a concentration of 3 mol/L, and refluxed at 60 ° C until the three-dimensional porous metal template was completely dissolved, and then washed and dried to obtain a three-dimensional graphene porous structure.
  • the test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.
  • CAD software is used to establish a three-dimensional porous unit body with a cell size of 1.5 mm, wherein the unit body array is designed as a periodic porous structure with a porosity of 80% and an ordered arrangement.
  • a pure nickel powder having a particle size distribution in the range of 10 to 30 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and the laser power was set to 300 W, the scanning speed was 600 mm/s, the layer thickness was 0.05 mm, and the scanning pitch was 0.1 mm.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by SLM technique.
  • porous metal nickel structure was placed in a 900 degree tube furnace, and heat treatment was performed for 10 hours under Ar gas protection.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (180 mL / min) and H 2 (200 mL / min); after holding for 30 minutes, the quartz was applied to the quartz. Styrene (0.508 mL/h) was introduced into the tube and reacted for 0.5 h. Finally, H 2 was turned off, and cooled to room temperature in an Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template in which graphene was grown was immersed in a hydrochloric acid/sulfuric acid mixed solution having a concentration of 2 mol/L, and refluxed at 90 ° C until the three-dimensional porous metal template was completely dissolved and then washed. After washing and drying, a three-dimensional graphene porous structure is obtained. The test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.
  • CAD software is used to establish a three-dimensional porous structure with a pore size distribution of 1 mm to 3 mm and a porosity of 90%, disorderedly arranged and interconnected.
  • a pure nickel powder having a particle size distribution in the range of 5 to 10 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and the vacuum was set to 5.0 ⁇ 10 -2 Pa, the scanning speed was 35 mm/s, the layer thickness was 0.02 mm, and the operating current was 3 mA.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by electron beam melting (EBM) technique.
  • EBM electron beam melting
  • the porous metal nickel structure was placed in a 1350 degree tube furnace, and after heat treatment for 12 hours under Ar gas protection, it was cooled with the furnace.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (200 mL / min) and H 2 (200 mL / min); after 60 minutes of incubation, the quartz was applied to the quartz. Styrene (0.254 mL/h) was introduced into the tube and reacted for 0.5 h. Finally, H 2 was turned off, and cooled to room temperature in an Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template with graphene was immersed in a ferric chloride solution with a concentration of 1 mol/L, and refluxed at 80 ° C until the three-dimensional porous metal template was completely dissolved, and then washed and dried to obtain a three-dimensional graphene porous. structure.
  • the test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.
  • CAD software is used to establish a three-dimensional porous structure with a pore size distribution of 0.5 mm to 2 mm and a porosity of 70%, disorderly arranged and interconnected.
  • pure copper powder having a particle size distribution in the range of 30 to 50 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and a fiber laser was used as the energy source.
  • the laser power was set to 300 W, the scanning speed was 600 mm/s, the layer thickness was 0.05 mm, and the scanning pitch was 0.1 mm.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by SLM technique.
  • the porous metal nickel structure was placed in a 1200-degree tube furnace, and under heat treatment for Ar gas, it was subjected to heat treatment for 12 hours and then cooled with the furnace.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (150 mL / min) and H 2 (250 mL / min); after 60 minutes of incubation, to quartz Methane (100 mL/h) was introduced into the tube and reacted for 0.5 h. Finally, H 2 was turned off, and cooled to room temperature in an Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template with graphene was immersed in a ferric chloride solution with a concentration of 1.5 mol/L, and refluxed at 80 ° C until the three-dimensional porous metal template was completely dissolved, and then washed and dried to obtain three-dimensional graphene. porous structure.
  • the test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.
  • CAD software is used to establish a three-dimensional porous unit body with a cell size of 2 mm, wherein the unit body array is designed as a periodic porous structure with a porosity of 50% and an ordered arrangement.
  • a pure nickel powder having a particle size distribution in the range of 20-30 ⁇ m was screened, and the powder had a nearly spherical surface.
  • a fiber laser was used as the energy source, and the laser power was set to 3000 W, the scanning speed was 600 mm/s, the layer thickness was 0.03 mm, and the scanning pitch was 0.08 mm.
  • a three -dimensional porous metal nickel structure having a size of 20 ⁇ 20 ⁇ 10 mm 3 was formed by direct metal laser sintering (DMLS) under the protection of argon.
  • DMLS direct metal laser sintering
  • porous metal nickel structure was placed in a 900 degree tube furnace, and heat treatment was performed for 24 hours under Ar gas protection.
  • the three-dimensional porous metal nickel structure is subjected to ceramic bead blasting. After the final ultrasonic cleaning, a three-dimensional porous nickel template is obtained;
  • the three-dimensional porous metal nickel template was placed in a tube furnace, and heated to 1000 ° C at 100 ° C / min in a mixed atmosphere of Ar (120 mL / min) and H 2 (250 mL / min); after holding for 45 minutes, the quartz was applied to the quartz. Styrene (0.508 mL/h) was introduced into the tube and reacted for 0.5 h. Finally, H 2 was turned off, and cooled to room temperature in an Ar (50 mL/min) atmosphere to obtain a three-dimensional graphene grown on the surface of the three-dimensional porous metal nickel.
  • porous metal nickel template in which graphene was grown was immersed in a hydrochloric acid solution having a concentration of 3 mol/L, and refluxed at 60 ° C until the three-dimensional porous metal template was completely dissolved, and then washed and dried to obtain a three-dimensional graphene porous structure.
  • the test results show that the three-dimensional graphene completely replicates the shape of the porous metal nickel template.

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Abstract

本发明公开了一种结构可控的三维石墨烯多孔材料制备方法，包括：构建三维多孔结构CAD模型，并通过增材制造技术制得相应形状的三维多孔金属结构；在惰性气体的保护氛围下，将所制得的三维多孔金属结构升温至900℃～1500℃，然后冷却至室温；然后进行喷砂和超声清洗处理以获得金属模板；通过化学气相沉积法在金属模板上生长石墨烯薄膜；配置腐蚀液并在60℃～90℃的温度下回流溶解金属模板，经洗涤和干燥处理后即得到三维石墨烯多孔材料产品。通过本发明，能够有效克服现有技术中所存在的外部形状和内部结构不可控的缺陷，同时具备便于操控、制备周期短和适应面广等特点，因而尤其适用于大批量规模生产高质量、多功能的三维石墨烯多孔材料的制造场合。

Description

一种结构可控的三维石墨烯多孔材料制备方法 【技术领域】
本发明属于石墨烯制备技术领域，更具体地，涉及一种结构可控的三维石墨烯多孔材料制备方法，尤其适于制备内部结构和外部形状均可获得有效、精密控制的三维石墨烯多孔材料产品。
【背景技术】
石墨烯是由单层碳原子构成的二维晶体材料，其不仅具有优异的电学性能(室温下的电子迁移率可达2×105cm2/V·s)、突出的热学性能(热导率达5000W/m·K)、超高的比表面积(2630m2/g)和极好的机械性能(杨氏模量达1100GPa，断裂强度125GPa)，而且还具有一些如完美的量子隧道效应等独特的性能。由于石墨烯材料具有如此众多的奇特优异性质，因而电子、信息、能源、材料和生物医药等领域具有巨大的应用前景。
为了综合利用石墨烯这一系列的优良性质，通常需要将二维的石墨烯组装成具有先进功能的三维石墨烯宏观结构。这样的三维宏观结构从微观角度来看除了拥有石墨烯的一些本征物理化学性能之外，还在可用比表面积、物质传输和活性催化剂负载等方面具有优势；从宏观角度来看，三维石墨烯更有利于实际应用、材料回收和大规模制备。
为此，现有技术中已经对其提出了一些解决方案。例如，CN102674321A中公开了一种用化学气相沉积法在三维泡沫镍模板表面沉积石墨烯薄膜，并经溶除多孔金属基底后得到多孔泡沫状石墨烯；CN103265022A公开了一种在导电基底上自发沉积三维石墨烯的方法；CN103910355A公开了一种以碳酸盐或碳酸氢盐为模版制备多孔贯通的三维石墨烯的方法，等等。
然而，进一步的研究表明，上述现有技术大多是依靠金属或非金属基底的自身结构来实现石墨烯的负载，进而建立三维多孔结构，这类方法在 很多程度上受到基底的约束，无法对更多的内部结构参数如孔径、孔隙率、孔型以及更为复杂的外部形状等进行精细控制；此外，现有的解决方案不易操控，因而无法满足对三维石墨烯宏观结构越来越高的应用需求。
【发明内容】
针对现有技术的以上缺陷或改进需求，本发明提供了一种结构可控的三维石墨烯多孔材料制备方法，其中通过对其制备工序以及关键工艺如三维多孔金属模板的制造和石墨烯的生长等环节进行研究和设计，相应可有效克服现有技术中所存在的外部形状和内部结构不可控的缺陷，同时具备便于操控、制备周期短和适应面广等特点，因而尤其适用于大批量规模生产高质量、多功能的三维石墨烯多孔材料的制造场合。
相应地，按照本发明，提供了一种结构可控的三维石墨烯多孔材料制备方法，其特征在于，该方法包括下列步骤：
(a)构建所需的三维多孔结构CAD模型，并对其外部形状和包括孔径、孔隙率和孔型在内的内部结构参数分别进行设计；
(b)基于步骤(a)所构建的CAD模型，通过增材制造技术采用金属粉末在惰性气体的保护氛围下制得相应形状的三维多孔金属结构；其中所采用的金属粉末选自镍、铜、铁或者钴，并且其平均粒径为5μm～50μm，其颗粒形状呈球形或者近似球形；
(c)继续在惰性气体的保护氛围下，将所制得的三维多孔金属结构升温至900℃～1500℃并保温4小时～24小时，然后冷却至室温；接着，对该三维多孔金属结构依次进行喷砂和超声清洗处理，由此获得三维多孔结构的金属模板；
(d)通过化学气相沉积法在步骤(c)所获得的金属模板上生长石墨烯薄膜：在此过程中，首先将金属模板放入管式炉中并在惰性气体和氢气的混合气氛下升温至800℃～1000℃，保温0.5小时～1小时后再将碳源引入继续执行反应，然后在惰性气体的保护气氛下冷却至室温，由此制得生 长在所述金属模板上的三维石墨烯；
(e)配置摩尔浓度为1mol/L～3mol/L的腐蚀液，并将步骤(d)所制得的产物浸入其中，在60℃～90℃的温度下回流直至将所述金属模板完全溶解，然后经洗涤和干燥处理后即得到三维石墨烯多孔材料产品，并且该三维石墨烯多孔材料产品包括孔径、孔隙率和孔型在内的内部结构参数以及其外部形状均与步骤(a)中所构建的CAD模型保持一致。
作为进一步优选地，在步骤(a)中，所述CAD模型呈现有序排列的周期性多孔结构或者随机排列的相互连通三维多孔结构，并且其单元尺寸在0.5mm～10mm之间。
作为进一步优选地，在步骤(b)中，所述增材制造技术包括选择性激光熔化、直接金属激光烧结或者电子束熔融技术，并且所述金属粉末的平均粒径进一步控制为10μm～30μm。
作为进一步优选地，在步骤(c)中，优选在氩气的保护氛围下，将所制得的三维多孔金属结构升温至1200℃～1370℃并保温12小时左右，然后冷却至室温。
作为进一步优选地，在步骤(d)中，所述碳源选自苯乙烯、甲烷或者乙烷，并且其流速被控制为0.2mL/h～200mL/h，引入后继续反应的时间为0.5小时～3小时。
作为进一步优选地，在步骤(d)中，所述惰性气体为氩气，并且其与氢气之间的体积配比为1:1～3:1，并且对于氩气和氢气的混合气氛而言，氩气的流速被控制为100mL/min～200mL/min，而氢气的流速被控制为180mL/min～250mL/min。
作为进一步优选地，在步骤(e)中，所述腐蚀液选自下列物质的一种或其混合：盐酸、硫酸、硝酸和氯化铁。
总体而言，通过本发明所构思的以上技术方案与现有技术相比，主要具备以下的技术优点：
1、通过采用构建CAD模型并在此基础上利用增材制造技术来加工对应的金属模板，能够根据需要获得各类指标均符合需求的三维石墨烯宏观结构，并能够对包括孔径、孔隙率和孔型在内的内部结构参数和复杂外形进行设计，相应地克服现有技术无法对三维石墨烯的结构和性能进行有效控制的缺陷；
2、通过对诸如金属模板的成型制造、石墨烯在金属模板上的生长和金属模板的腐蚀取出等关键环节进行研究，尤其是对其中涉及的重要反应参数和反应条件进行设计，该方法能够令人满意地制备完全复制对应CAD模型的三维石墨烯多孔材料；
3、按照本发明的制备方法原料来源广泛、绿色环保、低成本和低能耗，同时具备便于操控、制备周期短、成品率和设计自由度高等特点，因而尤其适应于大规模生产高质量且具备先进结构的多功能三维石墨烯多孔产品。
【附图说明】
图1是按照本发明的三维石墨烯多孔材料制备方法的工艺流程图。
【具体实施方式】
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。此外，下面所描述的本发明各个实施方式中所涉及到的技术特征只要彼此之间未构成冲突就可以相互组合。
实施例1
首先譬如采用CAD软件，相应建立单元尺寸为0.5mm的三维多孔单元体，其中将该单元体阵列设计为孔隙率为50％，有序排列的周期性多孔结构。
接着，筛选粒径分布在5-20μm范围内的纯镍粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，设置激光功率为200W,扫描速度 为500mm/s，层厚为0.01mm，扫描间距为0.08mm。在氩气的保护下，用选择性激光熔化(SLM)技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于1370度的管式炉中，在Ar气保护下，进行热处理10小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(180mL/min)和H2(200mL/min)混合气氛中以100℃/min升温至1000℃；保温30分钟后，向石英管中通入苯乙烯(0.254mL/h)，反应1h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为3mol/L的盐酸溶液，在80℃下回流直至将三维多孔金属模板完全溶解，再经洗涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
实施例2
首先譬如采用CAD软件，相应建立单元尺寸为1mm的三维多孔单元体，其中将该单元体阵列设计为孔隙率为75％，有序排列的周期性多孔结构。
接着，筛选粒径分布在30-50μm范围内的纯镍粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，设置激光功率为250W,扫描速度为700mm/s，层厚为0.02mm，扫描间距为0.08mm。在氩气的保护下，用直接金属激光烧结(DMLS)技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于1370度的管式炉中，在Ar气保护下，进行热处理12小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(180mL/min)和H2(200mL/min)混合气氛中以100℃/min升温至1000℃；保温45分钟后，向石英管中通入苯乙烯(0.508mL/h)，反应0.5h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为3mol/L的盐酸溶液，在60℃下回流直至将三维多孔金属模板完全溶解，再经洗涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
实施例3
首先譬如采用CAD软件，相应建立单元尺寸为1.5mm的三维多孔单元体，其中将该单元体阵列设计为孔隙率为80％，有序排列的周期性多孔结构。
接着，筛选粒径分布在10-30μm范围内的纯镍粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，设置激光功率为300W,扫描速度为600mm/s，层厚为0.05mm，扫描间距为0.1mm。在氩气的保护下，用SLM技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于900度的管式炉中，在Ar气保护下，进行热处理10小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(180mL/min)和H2(200mL/min)混合气氛中以100℃/min升温至1000℃；保温30分钟后，向石英管中通入苯乙烯(0.508mL/h)，反应0.5h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为2mol/L的盐酸/硫酸混合溶液，在90℃下回流直至将三维多孔金属模板完全溶解，再经洗 涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
实施例4
首先譬如采用CAD软件，相应建立孔径分布为1mm-3mm，孔隙率为90％，无序排列且相互连接的三维多孔结构。
接着，筛选粒径分布在5-10μm范围内的纯镍粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，设置真空度为5.0×10-2Pa,扫描速度为35mm/s，层厚为0.02mm，工作电流为3mA。在氩气的保护下，用电子束熔融(EBM)技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于1350度的管式炉中，在Ar气保护下，进行热处理12小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(200mL/min)和H2(200mL/min)混合气氛中以100℃/min升温至1000℃；保温60分钟后，向石英管中通入苯乙烯(0.254mL/h)，反应0.5h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为1mol/L的氯化铁溶液，在80℃下回流直至将三维多孔金属模板完全溶解，再经洗涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
实施例5
首先譬如采用CAD软件，相应建立孔径分布为0.5mm-2mm，孔隙率为70％，无序排列且相互连接的三维多孔结构。
接着，筛选粒径分布在30-50μm范围内的纯铜粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，采用光纤激光器作为能量源，设 置激光功率为300W,扫描速度为600mm/s，层厚为0.05mm，扫描间距为0.1mm。在氩气的保护下，用SLM技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于1200度的管式炉中，在Ar气保护下，进行热处理12小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(150mL/min)和H2(250mL/min)混合气氛中以100℃/min升温至1000℃；保温60分钟后，向石英管中通入甲烷(100mL/h)，反应0.5h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为1.5mol/L的氯化铁溶液，在80℃下回流直至将三维多孔金属模板完全溶解，再经洗涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
实施例6
首先譬如采用CAD软件，相应建立单元尺寸为2mm的三维多孔单元体，其中将该单元体阵列设计为孔隙率为50％，有序排列的周期性多孔结构。
接着，筛选粒径分布在20-30μm范围内的纯镍粉末，该粉末具有近球形的表面。采用光纤激光器作为能量源，设置激光功率为3000W,扫描速度为600mm/s，层厚为0.03mm，扫描间距为0.08mm。在氩气的保护下，用直接金属激光烧结(DMLS)技术成形尺寸为20×20×10mm3三维多孔金属镍结构。
接着，将多孔金属镍结构置于900度的管式炉中，在Ar气保护下，进行热处理24小时之后随炉冷却。再对三维多孔金属镍结构进行陶瓷珠喷砂处理。最后超声清洗后，获得三维多孔镍模板；
接着，将三维多孔金属镍模板放入管式炉中，在Ar(120mL/min)和H2(250mL/min)混合气氛中以100℃/min升温至1000℃；保温45分钟后，向石英管中通入苯乙烯(0.508mL/h)，反应0.5h；最后，关闭H2，在Ar(50mL/min)气氛下冷却至室温，就得到生长在三维多孔金属镍表面的三维石墨烯。
最后，将生长了石墨烯的多孔金属镍模板浸入浓度为3mol/L的盐酸溶液，在60℃下回流直至将三维多孔金属模板完全溶解，再经洗涤、干燥后即得到三维石墨烯多孔结构。测试结果表明，该三维石墨烯完整地复制了多孔金属镍模板的形状。
本领域的技术人员容易理解，以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (7)

  1. 一种结构可控的三维石墨烯多孔材料制备方法，其特征在于，该方法包括下列步骤：
    (a)构建所需的三维多孔结构CAD模型，并对其外部形状和包括孔径、孔隙率和孔型在内的内部结构参数分别进行设计；
    (b)基于步骤(a)所构建的CAD模型，通过增材制造技术采用金属粉末在惰性气体的保护氛围下制得相应形状的三维多孔金属结构；其中所采用的金属粉末选自镍、铜、铁或者钴等，并且其平均粒径为5μm～50μm，其颗粒形状呈球形或者近似球形；
    (c)继续在惰性气体的保护氛围下，将所制得的三维多孔金属结构升温至900℃～1500℃并保温4小时～24小时，然后冷却至室温；接着，对该三维多孔金属结构依次进行喷砂和超声清洗处理，由此获得三维多孔结构的金属模板；
    (d)通过化学气相沉积法在步骤(c)所获得的金属模板上生长石墨烯薄膜：在此过程中，首先将金属模板放入管式炉中并在惰性气体和氢气的混合气氛下升温至800℃～1000℃，保温0.5小时～1小时后再将碳源引入继续执行反应，然后在惰性气体的保护气氛下冷却至室温，由此制得生长在所述金属模板上的三维石墨烯；
    (e)配置摩尔浓度为1mol/L～3mol/L的腐蚀液，并将步骤(d)所制得的产物浸入其中，在60℃～90℃的温度下回流直至将所述金属模板完全溶解，然后经洗涤和干燥处理后即得到三维石墨烯多孔材料产品，并且该三维石墨烯多孔材料产品包括孔径、孔隙率和孔型在内的内部结构参数以及其外部形状均与步骤(a)中所构建的CAD模型保持一致。
  2. 如权利要求1所述的制备方法，其特征在于，在步骤(a)中，所述CAD模型呈现有序排列的周期性多孔结构或者随机排列的相互连通三维 多孔结构，并且其单元尺寸在0.5mm～10mm之间，孔隙率在20～90％之间可调。
  3. 如权利要求1或2所述的制备方法，其特征在于，在步骤(b)中，所述增材制造技术包括选择性激光熔化、直接金属激光烧结或者电子束熔融技术，并且所述金属粉末的平均粒径进一步控制为10μm～30μm。
  4. 如权利要求3所述的制备方法，其特征在于，在步骤(c)中，优选在氩气的保护氛围下，将所制得的三维多孔金属结构升温至1200℃～1370℃并保温12小时左右，然后冷却至室温。
  5. 如权利要求1-4任意一项所述的制备方法，其特征在于，在步骤(d)中，所述碳源选自苯乙烯、甲烷或者乙烷，并且其流速被控制为0.2mL/h～200mL/h，引入后继续反应的时间为0.5小时～3小时。
  6. 如权利要求1-5任意一项所述的制备方法，其特征在于，在步骤(d)中，所述惰性气体为氩气，并且其与氢气之间的体积配比为1:1～3:1，并且对于氩气和氢气的混合气氛而言，氩气的流速被控制为100mL/min～200mL/min，而氢气的流速被控制为180mL/min～250mL/min。
  7. 如权利要求6所述的制备方法，其特征在于，在步骤(e)中，所述腐蚀液选自下列物质的一种或其混合：盐酸、硫酸、硝酸和氯化铁。
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