Patent ID: 12224080

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A preferred embodiment of the present disclosure is an optically transparent and electrically conductive film composed of a mesh or meshes of metal nanowires and pristine graphene with a metal nanowire-to-graphene weight ratio of from 1/99 to 99/1, wherein the pristine graphene contains no oxygen and no hydrogen, and the film exhibits an optical transparence no less than 80% and sheet resistance no higher than 300 ohm/square. The film is thinner than 100 nm, more often thinner than 10 nm, even more often and preferably thinner than 2 nm, and can be as thin as 0.34 nm.

The two key components in this transparent and conductive film are metal nanowires (e.g. silver nanowires, AgNW) and pristine graphene.

Graphene normally refers to a sheet of carbon atoms that are arranged in a hexagonal lattice and the sheet is one carbon atom thick. This isolated, individual plane of carbon atoms is commonly referred to as single-layer graphene. A stack of multiple graphene planes bonded through van der Waals forces in the thickness direction with an inter-graphene plane spacing of 0.3354 nm is commonly referred to as a multi-layer graphene. A multi-layer graphene platelet has up to 300 layers of graphene planes (<100 nm in thickness). When the platelet has up to 5-10 graphene planes, it is commonly referred to as “few-layer graphene” in the scientific community. Single-layer graphene and multi-layer graphene sheets are collectively called “nano graphene platelets” (NGPs). Graphene sheets/platelets or NGPs are a new class of carbon nano material (a 2-D nano carbon) that is distinct from the 0-D fullerene, the 1-D CNT, and the 3-D graphite.

In the instant application and in keeping with commonly accepted definitions in scientific community, NGPs or graphene materials can include discrete sheets/platelets of single-layer and multi-layer pristine graphene, graphene oxide, or reduced graphene oxide with different oxygen contents. Pristine graphene has essentially 0% oxygen and 0% hydrogen. Graphene oxide (GO) has 0.01%-46% by weight of oxygen and reduced graphene oxide (RGO) has 0.01%-2.0% by weight of oxygen. In other words, RGO is a type of GO having lower but non-zero oxygen content. Additionally, both GO and RGO contain a high population of edge- and surface-borne chemical groups, vacancies, oxidative traps, and other types of defects, and both GO and RGO contain oxygen and other non-carbon elements, e.g. hydrogen. In contrast, the pristine graphene sheets are practically defect-free on the graphene plane and contain no oxygen. Hence, GO and RGO are commonly considered in the scientific community as a class of 2-D nano material that is fundamentally different and distinct from pristine graphene.

NGPs are commonly obtained by intercalating natural graphite particles with a strong acid and/or oxidizing agent to obtain a graphite intercalation compound (GIC) or graphite oxide (GO), as illustrated inFIG.1(a)(process flow chart) andFIG.1(b)(schematic drawing). The presence of chemical species or functional groups in the interstitial spaces between graphene planes serves to increase the inter-graphene spacing (d002, as determined by X-ray diffraction), thereby significantly reducing the van der Waals forces that otherwise hold graphene planes together along the crystallographic c-axis direction. The GIC or GO is most often produced by immersing natural graphite powder (20inFIGS.1(a)and100inFIG.1(b)) in a mixture of sulfuric acid, nitric acid (an oxidizing agent), and another oxidizing agent (e.g. potassium permanganate or sodium perchlorate). The resulting GIC (22or102) is actually some type of graphite oxide (GO) particles. Strong oxidation of graphite particles can result in the formation of a gel-like state called “GO gel”21. The GIC22is then repeatedly washed and rinsed in water to remove excess acids, resulting in a graphite oxide suspension or dispersion, which contains discrete and visually discernible graphite oxide particles dispersed in water. There are two processing routes to follow after this rinsing step:

Route 1 involves removing water from the suspension to obtain “expandable graphite,” which is essentially a mass of dried GIC or dried graphite oxide particles. Upon exposure of expandable graphite to a temperature in the range from typically 800-1,050° C. for approximately 30 seconds to 2 minutes, the GIC undergoes a rapid expansion by a factor of 30-300 to form “graphite worms” (24or104), which are each a collection of exfoliated, but largely un-separated graphite flakes that remain interconnected.

In Route 1A, these graphite worms (exfoliated graphite or “networks of interconnected/non-separated graphite flakes”) can be re-compressed to obtain flexible graphite sheets or foils (26or106) that typically have a thickness in the range from 0.1 mm (100 μm)-0.5 mm (500 μm). Alternatively, one may choose to use a low-intensity air mill or shearing machine to simply break up the graphite worms for the purpose of producing the so-called “expanded graphite flakes” (49or108) which contain mostly graphite flakes or platelets thicker than 100 nm (hence, not a nano material by definition).

Exfoliated graphite worms, expanded graphite flakes, and the recompressed mass of graphite worms (commonly referred to as flexible graphite sheet or flexible graphite foil) are all 3-D graphitic materials that are fundamentally different and patently distinct from either the 1-D nano carbon material (CNT or CNF) or the 2-D nano carbon material (graphene sheets or platelets, NGPs). Flexible graphite (FG) foils and all the expanded graphite films are totally dark and opaque, not suitable for use as a transparent conductive electrode.

In Route 1B, the exfoliated graphite is subjected to high-intensity mechanical shearing (e.g. using an ultrasonicator, high-shear mixer, high-intensity air jet mill, or high-energy ball mill) to form separated single-layer and multi-layer graphene sheets (collectively called NGPs, 33 or 112), as disclosed in our U.S. application Ser. No. 10/858,814. Single-layer graphene can be as thin as 0.34 nm, while multi-layer graphene can have a thickness up to 100 nm. In the present application, the thickness of multi-layer NGPs is typically less than 20 nm. The NGPs (still containing oxygen) may be dispersed in a liquid medium and cast into a GO thin film 34.

Route 2 entails ultrasonicating the graphite oxide suspension for the purpose of separating/isolating individual graphene oxide sheets from graphite oxide particles. This is based on the notion that the inter-graphene plane separation has been increased from 0.3354 nm in natural graphite to 0.6-1.1 nm in highly oxidized graphite oxide, significantly weakening the van der Waals forces that hold neighboring planes together. Ultrasonic power can be sufficient to further separate graphene plane sheets to form separated, isolated, or discrete graphene oxide (GO) sheets. These graphene oxide sheets can then be chemically or thermally reduced to obtain “reduced graphene oxides” (RGO) typically having an oxygen content of 0.01%-10% by weight, more typically 0.01%-5% by weight, and most typically 0.01%-2.0% by weight of oxygen with heavy chemical reduction using a reducing agent like hydrazine.

It is important to further emphasize the fact that, in the typical prior art processes, ultrasonification is used after intercalation and oxidation of graphite (i.e., after first expansion) and most typically after thermal shock exposure of the resulting GIC or GO (i.e., after second expansion or exfoliation) to aid in breaking up those graphite worms. There are already much larger spacings between flakes after intercalation and/or after exfoliation (hence, making it possible to easily separate flakes by ultrasonic waves). This ultrasonication was not perceived to be capable of separating those un-intercalated/un-oxidized layers where the inter-graphene spacing remains <0.34 nm and the van der Waals forces remain strong.

The applicant's research group was the very first in the world to surprisingly observe that, under proper conditions (e.g., with an ultrasonic frequency and intensity and under the assistance of a certain type of surfactant), ultrasonication can be used to produce ultra-thin graphene directly from graphite, without having to go through chemical intercalation or oxidation. This disclosure was reported in a patent application [A. Zhamu, et al., “Method of Producing Exfoliated Graphite, Flexible Graphite, and Nano Graphene Plates,” U.S. patent Ser. No. 11/800,728 (May 8, 2007); now U.S. Pat. No. 7,824,651 (Nov. 2, 2010)]. This “direct ultrasonication” process is capable of producing both single-layer and few-layer pristine graphene sheets. This innovative process involves simply dispersing pristine graphite powder particles 20 in a liquid medium (e.g., water, alcohol, or acetone) containing a dispersing agent or surfactant to obtain a suspension. The suspension is then subjected to an ultrasonication treatment, typically at a temperature between 0° C. and 100° C. for 10-120 minutes, resulting in ultra-thin pristine graphene sheets suspended in a liquid medium. The resulting suspension can be cast to form a pristine graphene film 38. No chemical intercalation or oxidation is required. The graphite material has never been exposed to any obnoxious chemical. This process combines expansion, exfoliation, and separation into one step. Hence, this simple yet elegant method obviates the need to expose graphite to a high-temperature, or chemical oxidizing environment. Upon drying, the resulting NGPs are essentially pristine graphene, containing no oxygen and no surface defects. These pristine graphene sheets, single-layer or multi-layer, are all highly conductive both electrically and thermally.

This direct ultrasonication process may be considered as peeling off graphene layers at a rate of 20,000 attempts per second (if the ultrasonic frequency is 20 kHz) or higher (if higher frequency) per each suspended graphite particle. The resulting NGPs are pristine graphene, being single-grain or single-crystalline and without any intentionally added or bonded oxygen or hydrogen. This is a powerful approach to large-scale preparation of pristine NGPs.

After additional research and development work, we further discovered that a surfactant is not needed if the graphite particles are mixed with a certain liquid or solvent that meets a specific surface energy requirement [A. Zhamu and Bor Z. Jang, U.S. Pat. No. 8,226,801, Jul. 24, 2012]. The resulting surfactant-free mixture of pristine graphitic particles (non-preintercalated, un-oxidized, un-fluorinated, etc.) and solvent is then subjected to direct ultrasonication. This improvement is significant since it eliminates the need to remove a surfactant from this liquid or solvent. The process is fast and environmentally benign. It can be easily scaled-up for mass production of highly conducting graphene. Again, it is important to emphasize that, in all prior art processes, ultrasonification was used after intercalation and oxidation of graphite (i.e., after first expansion) and, in most cases, after thermal shock exposure of the resulting GIC or GO (after second expansion). In contrast, the direct ultrasonication process does not involve pre-oxidizing or pre-intercalating the starting graphite particles.

In addition to the aforementioned direct ultrasonication, also referred to as liquid phase production, other processes can be used to produce pristine graphene. Examples are supercritical fluid exfoliation, graphite dissolution in select solvent (e.g. NMP), alkali metal intercalation and water-induced explosion, and more expensive epitaxial growth. The alkali metal intercalation route involves exposing graphite to an alkali metal melt or a molten mixture of two alkali metals (e.g. eutectic). This can be conducted at a temperature typically lower than 300° C., but in a highly controlled environment (e.g. inside a glovebox).

Normally, a pristine graphene is a single-grain or single-crystalline structure of hexagonal carbon atoms wherein the graphene plane is essentially defect-free except at the graphene plane edges. Further, the pristine graphene normally does not contain any non-carbon atoms (e.g. oxygen and hydrogen). The pristine graphene is fundamentally distinct from the CVD graphene, which is polycrystalline and inherently has a significant amount of non-carbon atoms chemically bonded thereto. Moreover, the CVD graphene contains many defects, e.g., grain boundaries, line defects, vacancies, and other lattice imperfections, such as those many carbon atoms that are arranged in pentagons, heptagons, or octagons, as opposed to the normal hexagon in pristine graphene. The term “pristine graphene” as claimed in the instant application inherently does not include the CVD graphene.

As indicated earlier, different types of NGPs have different oxygen contents. Pristine graphene has essentially 0% oxygen. Graphene oxide (GO) has 0.01%-46% by weight of oxygen and reduced graphene oxide (RGO) has 0.01%-2.0% by weight of oxygen. Both GO and RGO contains a high population of edge- and surface-borne chemical groups, vacancies, oxidative traps, and other types of defects, and both GO and RGO contain oxygen and other elements, e.g. hydrogen. Hence, GO and RGO are commonly considered in the scientific community as a class of 2-D nano material that is fundamentally different and distinct from pristine graphene. This distinction and difference in composition and structure is also reflected in many of their properties. For instance, GO is essentially an electrically insulating material. Even after heavy oxidation treatment, the resulting RGO still exhibits a relatively low electrical and thermal conductivity as compared to polycrystalline graphite. As an example, RGO thin films of approximate 10-30 nm thickness exhibit a typical electrical conductivity of 550-720 S/cm, even significantly lower than the 1,250 S/cm of polycrystalline graphite [Ref. 13; X. Wang, et al]. In contrast, the present study demonstrates that pristine graphene-based thin film sheets of comparable thickness exhibit an electrical conductivity of typically 5,000-15,000 S/cm. These pristine graphene sheets are practically defect-free, are single-crystalline, and contain no oxygen or hydrogen. The pristine graphene can be optionally doped with a chemical species, such as boron or nitrogen, to modify its electronic and optical behavior if so desired.

There are many processes, with or without a template, that can be used to produce metal nanowires, and these are well known in the art. A widely used approach to fabricate metal nanowires is based on the use of various templates, which include negative, positive, and surface step templates. Negative template methods use prefabricated cylindrical nano-pores in a solid material as templates. By depositing metals into the nano-pores, nanowires with a diameter predetermined by the diameter of the nano-pores are fabricated.

The positive template method uses wire-like nanostructures, such as DNA and carbon nanotubes as templates, and nanowires are formed on the outer surface of the templates. Unlike negative templates, the diameters of the nanowires are not restricted by the template sizes and can be controlled by adjusting the amount of materials deposited on the templates. By removing the templates after deposition, wire-like and tube-like structures can be formed.

Atomic-scale step edges on a crystal surface can be used as templates to grow nanowires. The method takes advantage of the fact that deposition of many materials on a surface often starts preferentially at defect sites, such as surface step-edges. For this reason, the method is sometimes called “step edge decoration.” As examples, several research groups prepared metal nanowires on vicinal single crystal surfaces using the physical vapor deposition (PVD) method. Others fabricated metal nanowires of 1-2 atomic layer thick with a controlled “width” and wire spacing.

Metal nanowires, CNTs, and/or pristine graphene may be dispersed in a liquid medium with or without a surfactant to form a solution, suspension, or ink. The graphene-, metal nanowire-, CNT-, or hybrid-based films may be deposited from solution, suspension, or ink using a variety of methods, including spray painting, drop casting, spin coating, vacuum-assisted filtration, electrostatic deposition, and dip coating.

In a spray painting process, the solution/suspension/ink can be spray painted onto a heated or non-heated substrate. The substrate may be rinsed during the spraying process to remove the solubilization agent, or surfactant. The spraying solution/suspension/ink may be of any concentration. The substrate surface may be functionalized to aid in adhesion of the deposited species (i.e., metal nanowires, CNTs, and/or graphene). The spraying rate and the number of spraying passes may be varied to obtain different amounts of deposited species.

In a drop casting process, a drop of the solution/suspension/ink can be placed onto a substrate for a period of time. The substrate may be functionalized to enhance adhesion of deposited species. The substrate with graphene may be rinsed by appropriate solvents. Alternatively, the solution can be spin-coated along with an appropriate solvent to remove the surfactant simultaneously. In dip coating, the substrate can be dipped into the solution for a period of time. This may form patterned or random networks of graphene, graphene/nanowire, or graphene/nanotube hybrids. In a printing process, the graphene network may be transferred from one substrate to another by means of a stamp. The stamp may be made from Polydimethyl-siloxane (PDMS). The transfer can be aided by gentle heating (up to 100° C.) and pressure. In a vacuum filtration process, the solution/suspension/ink can be filtered through a porous membrane under the assistance of a vacuum pump. A film of graphene, graphene/nanowire, and graphene/nanotube is deposited on top of the filtering membrane. The film can be washed while on the filter with a liquid medium to remove surfactant, functionalization agents, or unwanted impurities.

It may be noted that, for a coating or casting process, one may deposit the metal nanowires or CNTs to form a film first, which can be supported on a substrate. A protective graphene film is then deposited onto the nanowire or nanotube film. Alternatively, one may choose to disperse nanowires and/or nanotubes into a graphene solution/suspension to form a suspension or ink. Then, the nanowires and/or nanotubes are co-deposited with graphene to form an integral layer of conductive species.

The following examples serve to provide the best modes of practice for the present disclosure and should not be construed as limiting the scope of the disclosure:

Example 1: Direct Ultrasonication Production of Pristine Graphene from Natural Graphite in a Low Surface Tension Medium

As an example, five grams of natural graphite, ground to approximately 20 μm or less in sizes, were dispersed in 1,000 mL of n-Heptane to form a graphite suspension. An ultrasonicator tip was then immersed in the suspension, which was maintained at a temperature of 0-5° C. during subsequent ultrasonication. An ultrasonic energy level of 200 W (Branson 5450 Ultrasonicator) was used for exfoliation and separation of graphene planes from dispersed graphite particles for a period of 1.5 hours. The average thickness of the resulting pristine graphene sheets was 1.1 nm, having mostly single-layer graphene and some few-layer graphene.

Example 2: Preparation of Pristine Graphene from Natural Graphite in Water-Surfactant Medium Using Direct Ultrasonication

As another example, five grams of graphite flakes, ground to approximately 20 μm or less in sizes, were dispersed in 1,000 mL of deionized water (containing 0.15% by weight of a dispersing agent, Zonyl® FSO from DuPont) to obtain a suspension. An ultrasonic energy level of 175 W (Branson 5450 Ultrasonicator) was used for exfoliation, separation, and size reduction for a period of 1.5 hour. This procedure was repeated several times, each time with five grams of starting graphite powder, to produce a sufficient quantity of pristine graphene for thin film deposition.

Example 3: Pristine Graphene from Meso-Carbon Micro-Beads (MCMBs)

Five grams of artificial graphite, MCMBs (supplied from Shanghai Shan Shan Tech Co.) with an average particle size of approximately 18 μm, were dispersed in 1,000 mL of benzene. An ultrasonic energy level of 250 W (Branson 5450 Ultrasonicator) was used for the exfoliation and separation of graphene planes for a period of 1.5 hours. The average thickness of the resulting NGPs was 3.2 nm. When a lower surface tension liquid (Perfluorohexane, surface tension of 11.91 mN/m and contact angle of 23 degrees) was used, the average NGP thickness was 0.61 nm, indicating that most of the pristine graphene sheets were single-layer graphene.

Example 4: Preparation of Pristine NGPs from Natural Graphite Particles and MCMBs Using Potassium Intercalation

Natural graphite was obtained from Huadong Graphite Co., Qingdao, China. The first-stage intercalation compound, KC8, was synthesized by adding a stoichiometric amount of potassium, 81.4 mg (0.0021 moles) to 200 mg (0.0167 moles) of graphite particles in a Pyrex tube capped with a stopcock. All transfers were carried out in a helium filled dry box. The reactant filled tube was evacuated, sealed and heated for 16 hours at 200° C. The compound formed was bright gold in color. The obtained GIC was poured into a mixture of ethanol and distilled water (50:50 by volume). The material turns from gold to black as the graphite got exfoliated and bubbling was observed, suggesting that hydrogen was produced. The resulting solution was basic due to the formation of potassium ethoxide. The dispersion of nano graphene sheets in aqueous ethanol solution was then allowed to settle. The solvent was decanted and the product washed several times with ethanol until a neutral pH was obtained. Removal of water led to pristine NGP powder. Another batch of samples was prepared from MCMBs following the same procedures.

Example 5: Preparation of Pristine NGPs Using Supercritical Fluids

A natural graphite sample (approximately 5 grams) was placed in a 100 milliliter high-pressure vessel. The vessel was equipped with security clamps and rings that enable isolation of the vessel interior from the atmosphere. The vessel was in fluid communication with high-pressure carbon dioxide by way of piping means and limited by valves. A heating jacket was disposed around the vessel to achieve and maintain the critical temperature of carbon dioxide.

High-pressure carbon dioxide was introduced into the vessel and maintained at approximately 1,100 psig (7.58 MPa). Subsequently, the vessel was heated to about 70° C. at which the supercritical conditions of carbon dioxide were achieved and maintained for about 3 hours, allowing carbon dioxide to diffuse into inter-graphene spaces. Then, the vessel was immediately depressurized “catastrophically’ at a rate of about 3 milliliters per second. This was accomplished by opening a connected blow-off valve of the vessel. As a result, delaminated or exfoliated graphene layers were formed. This sample was found to contain pristine NGPs with an average thickness just under 10 nm.

Approximately two-thirds of the sample were subjected to another cycle of supercritical CO2intercalation and de-pressurization treatments (i.e., the above procedures were repeated), yielding much thinner NGPs with an average thickness of 2.1 nm. The specific surface area, as measured by the BET method, was approximately 430 m2/g. TEM and AFM examinations indicated that there were many single-layer graphene sheets in this sample.

Another sample was prepared under essentially identical supercritical CO2conditions, with the exception that a small amount of surfactant (approximately 0.05 grams of Zonyl® FSO) was mixed with 5 grams of natural graphite before the mixture was sealed in the pressure vessel. The resulting NGPs have a surprisingly low average thickness, 3.1 nm. After the pressurization and de-pressurization procedures were repeated for another cycle, the resulting NGPs have an average thickness less than 1 nm, indicating that a majority of the NGPs are single-layer or double-layer sheets. The specific surface area of this sample after a repeated cycle was approximately 900 m2/g. It is clear that the presence of a surfactant or dispersing agent promotes separation of graphene layers, perhaps by preventing the reformation of van der Waals forces between graphene sheets once separated.

Example 6: Thermal Exfoliation and Separation of Graphite Oxide

Graphite oxide was prepared by oxidation of graphite flakes with sulfuric acid, nitrate, and permanganate according to the method of Hummers [U.S. Pat. No. 2,798,878, Jul. 9, 1957]. Upon completion of the reaction, the mixture was poured into deionized water and filtered. The graphite oxide was repeatedly washed in a 5% solution of HCl to remove most of the sulfate ions. The sample was then washed repeatedly with deionized water until the pH of the filtrate was neutral. The slurry was spray-dried and stored in a vacuum oven at 60° C. for 24 hours. The interlayer spacing of the resulting laminar graphite oxide was determined by the Debye-Scherrer X-ray technique to be approximately 0.73 nm (7.3 Å).

Dried graphite oxide powder was then placed in a tube furnace maintained at a temperature of 1,050° C. for 60 minutes. The resulting exfoliated graphite was subjected to low-power ultrasonication (60 watts) for 10 minutes to break up the graphite worms and separate graphene oxide layers. Several batches of graphite oxide (GO) platelets were produced under identical conditions to obtain approximately 2.4 kg of oxidized NGPs or GO platelets. A similar amount of GO platelets was obtained and then subjected to chemical reduction by hydrazine at 140° C. for 24 hours. The GO-to-hydrazine molecular ratio was from 1/5 to 5/1. The resulting products are RGOs with various controlled oxygen contents.

Example 7: Preparation of Thin Films from Silver Nanowires (AgNW), AgNW/RGO Hybrid, and AgNW/Pristine Graphene Hybrid Materials

Silver nanowires were purchased from Seashell Technologies (La Jolla, CA, USA) as suspension in isopropyl alcohol with concentrations of 25 mg/ml. A small volume of dispersion was diluted down to approximately 1 mg/ml with isopropyl alcohol. This was subjected to half-an-hour sonication in a sonic bath. Then, this suspension was applied to a 50 mm×100 mm poly(ethylene terephthalate) (PET) substrates by a manually controlled wire-wound, i.e., pushing the suspension on top of the substrate with a rod.

In addition, AgNW films were prepared by spin-coating AgNW inks on glass substrates. To prepare AgNW films on glass substrates, we treated glass substrates with UV/Ozone to make hydrophilic surfaces for AgNW spin-coating. Then, AgNW ink was spin-coated on a glass substrate and then dried at 120° C. for 5 min. Several AgNW films were prepared by changing spin-coating speed from 250 to 2,000 rpm to investigate the effect of spin-coating speed on optical and electrical properties of AgNW films. Transparent electrode films of AgNW-RGO and AgNW-pristine graphene hybrid were also prepared in a similar manner. Separately, the AgNW-graphene hybrid transparent electrode films were prepared by coating RGO or pristine graphene onto the AgNW film.

An UV/Vis/NIR was used to measure the optical transmittance of AgNW, AgNW-RGO, and AgNW-pristine graphene films. The sheet resistances were measured by a non-contact Rs measurement instrument. The sheet resistance and optical transparency data of thin films prepared from various different materials and conditions are summarized inFIG.2(a)andFIG.2(b). Several significant observations can be made from these figures: (A) The AgNW-pristine graphene films significantly out-perform both AgNW and AgNW-RGO films in terms of high transmittance and/or low sheet resistance. (B) With hybrid AgNW-pristine graphene films, we were able to achieve a sheet resistance value of 54 and 43Ω/□ at 95% and 97% transmittance, respectively. These values are superior to those of un-doped CVD graphene or CVD graphene-AgNW films. These outstanding combined performances are achieved by using highly scalable, more cost-effective, less tedious, and vacuum equipment-free processes. This is most surprising. (C) Sheet resistance values as low as 10 and 8Ω/□ have been obtained, which are comparable to or better than those of high-end ITO glass. These surprisingly low sheet resistance values were achieved at an optical transmittance higher than 80%.

Example 8: Fabrication of Organic Photovoltaic Devices with AgNW, AgNW-RGO, and AgNW-Pristine Graphene Transparent Electrodes

To test the performance of AgNW-RGO film as the transparent electrode in an electro-optic device, we used AgNW, AgNW-RGO, and AgNW-pristine graphene films as anode layers in bulk heterojunction polymer solar cells as examples. First, an AgNW pattern for the anode layer was prepared onto a glass substrate by spin coating and a photolithography process. Then, for the AgNW-RGO and AgNW-pristine graphene transparent electrodes, patterned AgNW film was dipped into the aqueous solution of RGO or pristine graphene. The bulk heterojunction solar cells were then fabricated on the transparent electrode with a 30 nm of poly(3,4-ethylenedioxy thiophene):poly(styrenesulfonate) (PEDOT:PSS), 100 nm of a P3HT and PCBM blend with a 1:1 ratio, and LiF/Al cathode.

Further specifically, an AgNW transparent electrode was placed in an UV/O3chamber for 3 minutes and immediately spin-coated with a poly-3,4-ethyleneoxythiophene:poly-4-sytrensulfonate (PEDOT:PSS). The thickness of the spin-coated layer was approximately 20 nm, and then the PEDOT:PSS coated AgNW glass substrate was annealed on a hot plate for 10 min at 150° C. in a glove box. Poly(3-hexylthiophene) (P3HT) and [6,6]-phenyl-C61-butyric acid methyl ester (PCBM), which were blended in a weight ratio of 1:1, were dissolved in dichlorobenzene. Next, the P3HT:PCBM solution was spin-coated on top of the PEDOT:PSS layer and dried for 60 min at 50° C. and then annealed for 10 min at 100° C. in a glove box to form an active layer with a thickness of 100 nm. Lastly, a cathode layer composed of a LiF layer (1 nm) and an Al layer (120 nm) was deposited by thermal evaporation with the shadow mask in a high vacuum thermal evaporator (<10−6torr). The final products are the organic solar cell devices with a transparent electrode/PEDOT:PSS (30 nm)/P3HT:PCBM (100 nm)/LiF (1 nm)/Al (120 nm) configuration.

The Current density-voltage (J-V) measurements of organic solar cell devices were performed under 100 mW/cm2AM 1.5 G illuminations. All measurements were carried out under ambient conditions at room temperature.FIG.3shows the current density-voltage (J-V) characteristics of bulk heterojunction polymer solar cells with AgNW, AgNW-RGO, and AgNW-pristine graphene transparent electrodes under illumination. The solar cells with AgNW-RGO transparent electrode show an open-circuit voltage (Voc) of 0.49, short-circuit current density (Jsc) of 6.38 mA/cm2, and fill factor (FF) of 32.95, resulting in power conversion efficiency (PCE) of 1.03%. The devices with the AgNW transparent electrode exhibit a PCE is 1.21% with a Vocof 0.49 V, a Jscof 6.45 mA/cm2, and a FF of 38.26. In contrast, the devices with the AgNW/pristine graphene transparent electrode exhibit a PCE is 1.21% with a Vocof 0.49 V, a Jscof 6.75 mA/cm2, and a FF of 38.95. This result clearly indicates that the solar cells with AgNW-pristine graphene transparent electrode out-perform those with an AgNW or AgNW-RGO transparent electrode.

Example 9: Copper Nanowire (CuNW) Film, RGO Film, CuNW/RGO Hybrid Film, Pristine Graphene Film, CuNW/Pristine Graphene Film

In one preferred approach, the preparation of CuNW relied upon the self-catalytic growth of Cu nanowires within a liquid-crystalline medium of hexadecylamine (HAD) and cetyltriamoninum bromide (CTAB). First, HDA and CTAB were mixed at an elevated temperature to form a liquid-crystalline medium. Upon addition of the precursor, copper acetylacetonate [Cu(acac)2], long nanowires with excellent dispersibility form spontaneously within the medium in the presence of a catalytic Pt surface.

Specifically, a solution process was followed to prepare copper nanowires (CuNWs). As an example, 8 g HAD and 0.5 g CTAB were dissolved in a glass vial at 180° C. Then, 200 mg copper acetylacetonate was added and magnetically stirred for 10 minutes. Subsequently, a silicon wafer (0.5 cm2) sputtered with ˜10 nm of platinum was placed into the vial. The mixtures were then maintained at 180° C. for 10 hours, resulting in the formation of reddish cotton-like sheets settled at the bottom. After rinsing with toluene for several times, the nanowires were dispersed in toluene at different solid contents. The suspensions were separately cast into thin films on glass or PET surface. Several CuNW films supported on glass or PET substrate were then deposited with either RGO film or pristine graphene film.

The sheet resistance and optical transparency data of these films are summarized inFIG.4. Several significant observations can be made by examining the data from this chart: (A) The CuNW-pristine graphene films significantly out-perform both CuNW and CuNW-RGO films in terms of high transmittance and/or low sheet resistance. (B) With hybrid CuNW-pristine graphene films, we were able to achieve a sheet resistance value of 144 and 98Ω/□ at 93% and 91% transmittance, respectively. These values are superior to those of all CuNW-based electrodes ever reported. These outstanding combined performances are achieved by using highly scalable, more cost-effective, less tedious, and vacuum equipment-free processes. (C) Sheet resistance values as low as 30 and 19Ω/□ have been obtained, which are comparable to those of ITO glass. These surprisingly low sheet resistance values were achieved at an optical transmittance of 82% and 84%, respectively. These are most impressive and surprising considering the fact that the electrical conductivity of Cu is an order of magnitude lower than that of silver and, hence, one would not have expected such a low sheet resistance associated with CuNW even when in combination with graphene, which is even lower than Cu in electrical conductivity.

Example 10: CNT Film, RGO Film, CNT/RGO Hybrid Film, Pristine Graphene Film, CNT/Pristine Graphene Film

CNTs, RGO, pristine graphene, and their hybrid films were prepared using spin-coating. As an example, 5 mg of arc-discharged P3SWCNT (Carbon Solutions, Inc.) and 1 mg of graphite oxide paper were directly dispersed into a solution of 98% hydrazine (Sigma Aldrich) and allowed to stir for three days. All materials were used as received. Subsequent to stirring, the stable dispersion was centrifuged to separate out any CNT bundles and aggregated RGO particles. After centrifugation, uniformity of the dispersion was further ensured by heating to 60° C. with repeated ultrasonic agitation for 30 min. The resulting colloid was transferred into a nitrogen filled glove box for use in spin-coating.

For use as substrates, glass and PET films were cleaned in a combination of reagent grade acetone and isopropyl alcohol solution and pre-treated for 5 minutes by oxygen plasma in order to ensure good wetting by hydrazine. All substrates were transferred into the dry box and spin-coated within 15 minutes of this pre-treatment. After deposition, the films were heated to 115° C. to remove residual hydrazine. The sheet resistance and transmittance data of various transparent conductive films are shown in Table 1 below. Booth RGO and pristine graphene sheets used in the present study are single-layer or few layer graphene. These data indicate that thin films with combined pristine graphene-CNTs significantly out-perform CNT films, RGO films, and combined RGO-CNT films. The longstanding problem of high sheet resistance associated with CNT films, RGO films, and combined RGO-CNT films having a transmittance no less than 90% (an industry requirement) is now overcome.

TABLE 1Sheet resistance and transmittance data of various transparent conductive films.CNT filmRGOCNT/RGOPristine graphene (PG)CNT/PG1stset of samplesSheet21 kΩ/□475 kΩ/□620 Ω/□260 Ω/□110 Ω/□resistanceTransmittance90%94%90%95%92%2ndset of samplesSheet5.82 kΩ/□210 Ω/□resistanceTransmittance92%95%

In summary, a novel and unique class of transparent and conductive electrodes has been developed. This new class of hybrid materials surprisingly offers the following special features and advantages:(a) Thin films containing networks of metal NWs or carbon nanotubes combined with pristine graphene sheets prepared through solution processing techniques are a promising replacement to ITO glass due to their exceptionally high conductivity (low resistance) and optical transmittance. As an example, the superior performance of transparent pristine graphene-Ag NW electrodes on glass substrates and their use in organic solar cells have been demonstrated.(b) Even though Cu has a much lower electrical conductivity as compared with silver, the CuNW-pristine graphene electrodes still surprisingly provide excellent combination of high optical transparency and low sheet resistance.(c) Even though CNTs have a much lower electrical conductivity as compared with copper and silver, the CNT-pristine graphene electrodes still surprisingly provide excellent combination of high optical transparency and low sheet resistance suitable for a wide variety of electro-optical device applications.(d) Pristine graphene (single-grain, oxygen-free, and hydrogen-free) is significantly more effective than reduced graphene oxide and CVD graphene in terms of imparting electrical conductance to the metal nanowire or carbon nanotube films without compromising the optical transmittance. This has been quite unexpected.(e) The presently invented pristine graphene-AgNW films are particularly useful for organic optoelectronic devices such as organic photovoltaic (OPV) cells, organic light-emitting diodes, and organic photo-detectors because they can be deposited on flexible, light-weight substrates using low-cost fabrication methods.(f) An important aspect of optoelectronic thin-film devices is the transparent, conductive electrode through which light couples in or out of the devices. Indium tin oxide (ITO) is widely used but may be too expensive for an application such as solar cells. Moreover, metal oxides such as ITO are brittle and therefore of limited use on flexible substrates. The present disclosure provides a substitute for ITO with a similar sheet resistance and transparency performance, but at a lower cost, higher flexibility, durability, and integrity.(g) Graphene is a promising transparent conductor because of its unique optical and electrical properties. In principle, electrons in individual graphene sheets delocalize over the complete sheet, which provide ballistic charge transport in a one-atom-thick material with very little optical absorption. In practice, however, graphene films produced via CVD or via solution processing of graphene oxide (GO), reduced graphene oxide (RGO), and functionalized graphene contain multiple grain boundaries, lattice defects, oxidative traps, and/or other non-carbon elements that increase the electrical resistance of the material. The CVD graphene also inherently contains non-hexagonal carbons, which also impedes electron flow. As a result, the films must be made thicker than 1-4 atomic layer(s) to obtain practical sheet resistances. The use of pristine graphene, in combination with highly conductive metal nanowires or carbon nanotubes, has overcome this deficiency that has been a critically important yet challenging problem for quite some time.