Large-Sized Graphene Transfer via Edge Gap Extraction
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Solution Overview
Problem
Current methods for manufacturing and transferring larger-sized graphene layers are inefficient due to time-consuming wet etching and limitations in the stamp method, which struggles with larger sizes.
Innovation Solution
A method involving forming a graphene layer on a substrate with a catalyst layer, protection layer, and adhesive layer, followed by substrate removal using a hydrophilic liquid to weaken adhesion, and then transferring the graphene layer onto another substrate using a contact solution and sequential removal of layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wet etching is used to remove substrate from larger-sized graphene layer, then substrate removal is achieved, but processing time becomes excessively long
Solution Approach 1:
The invention extracts and removes the substrate from beneath the graphene layer through a gap created at the edge, allowing rapid removal without time-consuming etching of the entire substrate area. The substrate is separated by introducing a liquid through the gap and peeling away the substrate from the catalyst layer.
Solution Approach 2:
The invention performs preliminary actions by forming a gap at the edge of the substrate before substrate removal. This gap is created by selectively removing material or creating a separation zone, which enables subsequent rapid substrate extraction without requiring complete etching of the substrate.
2Ease of operation
If stamp method is used to transfer graphene layer, then transfer process is simplified, but it is not conducive to transferring larger-sized graphene layers
Solution Approach 1:
The invention segments the transfer process into distinct stages: forming a gap at the edge, introducing liquid through the gap, peeling the substrate away, and then transferring the graphene layer to the target substrate. This segmentation allows handling of large-area graphene layers that cannot be transferred using conventional stamp methods.
3Productivity
If conventional manufacturing methods are used for larger-sized graphene, then graphene layer formation is achieved, but processing efficiency is low
Solution Approach 1:
The invention performs preliminary actions by forming protection and adhesive layers on the graphene layer before substrate removal. These pre-formed layers facilitate subsequent substrate extraction and graphene transfer operations, enabling efficient processing of large-area graphene without increasing overall process complexity.
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 efficient transfer and manufacturing of larger-sized graphene layers, such as those exceeding 6 inches, with improved processing time and scalability.
Implementation Method 1
penetrating a hydrophilic liquid into a gap between the catalyst layer and the substrate
Implementation Method 2
coating a contact solution on the transferring substrate; and sliding the graphene layer onto the transferring substrate
Data Source
AI summary
Example embodiments relate to methods of manufacturing and transferring a larger-sized graphene layer. A method of transferring a larger-sized graphene layer may include forming a graphene layer, a protection layer, and an adhesive layer on a substrate and removing the substrate. The graphene layer may be disposed on a transferring substrate by sliding the graphene layer onto the transferring substrate.