Graphene Coated Copper Wire Grain Boundary Control
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Solution Overview
Problem
The miniaturization of electronics faces challenges such as increased resistance and heat generation in copper wires due to reduced diameter, and existing methods for coating metal structures with graphene result in polycrystalline graphene with grain boundaries, diminishing its unique properties.
Innovation Solution
A continuous method involving a roll-to-roll system where a metal substrate is heated to form a molten layer, contacted with a carbon source gas to form a graphene-comprising layer, and then solidified, effectively eliminating grain boundaries and enhancing the quality of the graphene coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical vapor deposition is used to deposit graphene on polycrystalline copper, then graphene coating is achieved, but grain boundaries are formed which diminish the unique properties of graphene
Solution Approach 1:
The patent applies parameter changes by controlling the substrate temperature to remain below the melting point of copper during CVD processing. This temperature parameter control prevents grain boundary formation in the underlying copper substrate, thereby enabling the growth of high-quality graphene without the detrimental effects of polycrystalline grain boundaries while maintaining the simplicity of the CVD process
Solution Approach 2:
The patent employs composite materials by using a specific copper substrate composition and structure that, when combined with controlled CVD processing, produces a composite system where the copper substrate serves as a grain boundary-free template for high-quality graphene growth, resolving the contradiction between manufacturing precision and ease of manufacture
2Length of moving object
If wire diameter is reduced to enable miniaturization, then electronic device size is reduced, but resistance and heat generation increase tremendously
Solution Approach 1:
The patent applies composite materials by creating a graphene-coated copper wire structure where the graphene layer serves as a protective and functional coating. This composite structure allows the use of reduced wire diameters while the graphene coating compensates for the increased resistance and heat generation by providing superior electrical conductivity and thermal management, thereby maintaining wire performance despite miniaturization
Solution Approach 2:
The patent applies local quality by providing a graphene coating specifically on the wire surface where electrical current flows. This localized enhancement of electrical and thermal properties at the critical interface allows the wire to maintain high performance despite reduced overall diameter, addressing the reliability concerns of miniaturized interconnects
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
This method produces high-quality graphene coatings on metal substrates, reducing grain boundaries and improving the properties of the graphene, thereby addressing the challenges of resistance and heat generation in miniaturized electronics.
Implementation Method 1
heating the metal substrate to form a molten metal layer on a first surface of the metal substrate
Implementation Method 2
heating the metal substrate to form a molten metal layer
Implementation Method 3
contacting the molten metal layer with a carbon source gas, such as a gas comprising hydrocarbon, to form a graphene-comprising layer
Implementation Method 4
solidifying the molten metal layer
Data Source
AI summary
A continuous method for preparing a metal substrate having a graphene-comprising coating, the method including providing a metal substrate, continuously advancing the metal substrate into and through a processing chamber, the processing chamber having one or more heating elements, providing electromagnetic radiation to the metal substrate via the one or more heating elements to heat the metal substrate, wherein heating the metal substrates forms a molten metal layer on a top surface of the metal substrate, contacting the molten metal layer with a carbon source gas to form a graphene-comprising coating substantially covering the molten metal layer of the top surface of the metal substrate, solidifying the molten metal layer, and advancing the metal substrate having the graphene-comprising coating out of the processing chamber.