Reel-to-Reel (100) Single-Crystal Copper Foil Growth
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Solution Overview
Problem
Existing methods for preparing large-area (100) single-crystal copper foil are inefficient, costly, and difficult to scale, with the Czochralski method being energy-intensive and limited to (111) crystal plane preparation.
Innovation Solution
A continuous preparation method involving a reel-to-reel process with controlled stress application in a temperature gradient heat treatment, using a carbon-based substrate and reducing atmosphere to dominate strain energy for grain boundary migration and lattice rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the Czochralski method is used to prepare single-crystal copper foil, then single crystal orientation is achieved, but energy consumption is high and large-scale preparation is difficult
Solution Approach 1:
The patent replaces the mechanical Czochralski pulling method with a heat treatment process that uses thermal energy and stress control to induce lattice rotation and grain boundary migration, transforming the preparation mechanism from mechanical to thermal-physical
Solution Approach 2:
The patent changes the preparation parameters by controlling temperature gradient (1-10°C/cm), stress (80-100 N/cm²), and atmosphere (reducing/protective) during heat treatment to achieve single-crystal transformation without the energy-intensive Czochralski process
2Stability of the object's composition
If the Czochralski method is used to prepare single-crystal copper foil, then single crystal orientation is achieved, but the preparation process is complicated and cost is high
Solution Approach 1:
The patent replaces the complex multi-step mechanical Czochralski process with a simplified heat treatment process using a tube furnace, reducing device complexity from specialized pulling equipment to standard heat treatment equipment
Solution Approach 2:
The patent extracts and eliminates the intermediate step of preparing single-crystal copper ingots, directly transforming commercial poly-crystal copper foil into single-crystal foil through heat treatment, simplifying the overall process
3Stability of the object's composition
If the Czochralski method is used to prepare single-crystal copper foil, then single crystal orientation is achieved, but thickness control to micron level is difficult
Solution Approach 1:
The patent achieves precise thickness control by adjusting heat treatment parameters (temperature, time, stress) rather than mechanical parameters, enabling micron-level precision through thermal-physical control
4Area of stationary object
If heat treatment is applied to prepare single-crystal copper foil, then large-area (111) single-crystal foil is obtained, but (100) single-crystal foil cannot be prepared
Solution Approach 1:
The patent changes the crystal plane orientation by adjusting the stress parameter applied during heat treatment, enabling control over which crystal plane ((100) or (111)) becomes the dominant surface orientation
Solution Approach 2:
The patent applies localized stress control to induce specific lattice rotations that favor (100) plane orientation, creating local conditions that direct the crystal growth toward the desired orientation
5Ease of manufacture
If commercial poly-crystal copper foil is used as starting material, then preparation process is simplified, but single-crystal transformation is not achievable without stress control
Solution Approach 1:
The patent applies preliminary stress control during the heat treatment process to prepare the poly-crystal structure for transformation, creating the conditions necessary for single-crystal formation before the actual grain boundary migration occurs
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 controllable production of large-area (100) single-crystal copper foil with high repeatability and reduced energy consumption, facilitating batch production and lowering costs.
Implementation Method 1
the large-area (100) single-crystal copper foil is prepared by applying a stress in a heat treatment process in a reducing/protective atmosphere under an environment with a temperature gradient
Implementation Method 2
an environment with a temperature gradient
Implementation Method 3
applying a stress for 10 minutes to 30 minutes
Implementation Method 4
strain energy in a growth process of the single-crystal copper foil is controlled to be dominant
Implementation Method 5
a carbon-based substrate placed on a corundum plate or a quartz plate as a support below the copper foil
Implementation Method 6
in a reducing/protective atmosphere
Data Source
AI summary
Disclosed is a continuous preparation method of a large-area (100) single-crystal copper foil, a poly-crystal copper foil is connected to a reel-to-reel device, a carbon-based substrate is placed below the copper foil, and the large-area (100) single-crystal copper foil is prepared by applying a stress in a heat treatment process in a reducing/protective atmosphere under an environment with a temperature gradient. According to the invention, the stress is applied to the copper foil for the first time, and strain energy of the copper foil is accurately regulated and controlled, so as to make the strain energy become a main influence factor of grain boundary migration and lattice rotation, so that the strain energy in a growth process of the single-crystal copper foil is controlled to be dominant, and the large-area (100) single-crystal copper foil is controllably prepared through heat treatment in the reducing atmosphere.