Large-Area Carbon Coating via Adhesive Transfer

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Solution Overview

Problem

Current methods for creating large-area carbon coatings are expensive, energy-intensive, and time-consuming, particularly for films thinner than 100 nm, and struggle to produce thicker coatings on large substrates in a rapid and cost-effective manner.

Innovation Solution

A method involving a substrate with a carbon coating and an adhesive layer, where the carbon coating can be up to 5 mm thick and cover over 100 m², using graphene and an adhesive layer composed of various materials, including animal, plant, and synthetic adhesives, applied using a carbon source and an adhesive roller, with the option of electrostatic charging for adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to create thin carbon films (less than 100 nm), then the films can be formed with desired thickness and morphology, but the process requires expensive and high-energy technologies with long deposition times

Engineering Contradiction:

Improvefilm thickness controlVSAvoiddeposition speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the fundamental deposition parameters by using adhesive transfer instead of direct deposition. This involves changing the state of the carbon source from vapor phase (in CVD) to solid adhesive-bound form, and changing the deposition mechanism from chemical reaction to physical adhesion, enabling rapid transfer without long deposition times while maintaining thin film precision

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces an adhesive layer as an intermediary carrier. The carbon coating is first deposited on a sacrificial substrate with adhesive, then transferred to the target substrate. This intermediary approach decouples the deposition process from the final application, allowing rapid transfer while maintaining film quality

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If conventional methods are used to create thicker carbon coatings on large-area substrates, then the desired thickness can be achieved, but the process is time-consuming and expensive

Engineering Contradiction:

Improvecoating thicknessVSAvoidgrowth time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The patent performs preliminary action by pre-depositing the carbon coating on a sacrificial substrate where conditions are optimized for deposition. The adhesive is applied in advance to the sacrificial substrate, allowing the carbon to be deposited under controlled conditions before rapid transfer to the large-area target substrate, eliminating time-consuming in-situ deposition on the final substrate

Inventive Principle:

Principle #10Preliminary action

3Reliability

If expensive high-energy technologies are used to form carbon coatings, then films with desired properties can be produced, but the manufacturing cost increases

Engineering Contradiction:

Improvecoating qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses a disposable sacrificial substrate that can be inexpensive and single-use. The adhesive-bound carbon coating is deposited on this sacrificial substrate, then transferred to the target substrate. The sacrificial substrate is discarded after transfer, eliminating the need for expensive, complex equipment on the target substrate and reducing manufacturing costs while maintaining coating quality

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent replaces complex high-energy deposition systems (like CVD reactors) with a simple mechanical adhesive transfer system. Instead of using expensive vacuum chambers and plasma generators, the method uses adhesive bonding and mechanical transfer, dramatically reducing equipment costs and manufacturing complexity while producing reliable carbon coatings

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the production of large-area, thin to thick carbon coatings with high optical transparency and uniformity, suitable for applications in electronics and vehicle surfaces, while being cost-effective and energy-efficient.

Implementation Method 1

an adhesive layer disposed between and immediately adjacent to the substrate surface and the carbon coating

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the carbon coating can be adhered to the substrate by an electrostatic charge

Methodology Applied

Scientific EffectElectrostatic adhesion: Electrostatics

Data Source

PatentUS10801104B2Methods and apparatuses for forming large-area carbon coatings

Publication Date: 2020.10.13 THE BOEING CO

AI summary

In one aspect, methods of making a carbon coating are described herein. In some implementations, a method of making a carbon coating comprises applying a first adhesive material to a substrate surface to provide an adhesive surface; rolling a carbon source over the adhesive surface to provide a carbon layer on the adhesive surface; and rolling an adhesive roller over the carbon layer to remove some but not all of the carbon of the carbon layer to provide the carbon coating.