In situ growth of three-dimensional graphene coatings on arbitrary-shaped micro/nano materials and its mechanism studies

In the past decade, there have been great advances in the controllable growth of two-dimensional (2D) graphene sheets. However, the preparation of 3D structured graphene such as graphene coatings on arbitrary-shaped micro/nano materials still remains a formidable challenge. Herein, we have proposed a general strategy for the in situ growth of 3D graphene coatings on the micro/nano particles with arbitrary shapes. Inspired by the CVD growth mechanism of 2D graphene sheets on the bulk metal substrates, we have in situ constructed a nanometer-thick catalytic interface on the micro/nano particle surface by introducing a trace amount of transition metal salts and solid carbon sources with strictly-controlled content and ratio. Growth of 3D graphene coatings is accomplished through a solid-state reaction. Under the catalysis of the in situ formed catalytic interface consisting of highly-ordered metal nanoislands, the nano-thick amorphous carbon layer which arousing from the pyrolysis of carbon sources can be effectively transformed into a continuous and uniform graphene coating throughout the material surface based on a dissolution-precipitation mechanism. 3D graphene coatings have been successfully grown on lithium iron phosphate, silver, copper and silicon particles. The growth mechanism of the 3D graphene coatings has been studied in detail and a growth model is also proposed. (C) 2015 Elsevier Ltd. All rights reserved.