Roll-to-roll graphene synthesis via electrolytic catalyst removal
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Solution Overview
Problem
Current graphene production methods, particularly chemical vapor deposition (CVD), are hindered by high costs due to the need for expensive substrates and polymers for graphene transfer, limiting scalability and market integration, with production costs exceeding $20 per square meter.
Innovation Solution
A method involving roll-to-roll electroplating to form a catalyst-coated support for graphene synthesis, where a catalyst film is deposited on a support and then electrolytically removed, allowing simultaneous graphene transfer to a desired substrate, reducing the amount of catalyst used and enabling lower synthesis temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If chemical vapor deposition (CVD) is used to produce graphene on copper foil, then large-area films can be produced, but production costs exceed $20 per square meter due to expensive substrates and polymer transfer materials
Solution Approach 1:
The patent extracts and removes the expensive copper substrate and polymer transfer materials from the conventional CVD process. By using a disposable thin copper foil that is electrolytically removed and eliminating the need for PMMA polymer support, the method eliminates the primary cost drivers while maintaining large-area graphene production capability.
Solution Approach 2:
The patent changes the thickness parameter of the copper substrate from conventional thick copper foil to ultra-thin copper foil (1-10 micrometers). This parameter change reduces material cost while maintaining sufficient catalytic activity for graphene growth, and enables electrolytic removal of the substrate after graphene transfer.
2Reliability
If conventional CVD with thick copper foil is used, then graphene can be synthesized, but substrate loss and transfer complexity increase costs
Solution Approach 1:
The patent extracts the copper substrate from the final graphene product structure by electrolytically removing it after graphene growth. The thin copper foil serves only as a temporary catalyst support during synthesis, then is completely removed via electrolysis, eliminating substrate loss in the final product and reducing waste.
Solution Approach 2:
The patent implements a discard-and-recover system where the thin copper foil is discarded after single-use graphene synthesis, and the expensive polymer transfer materials are eliminated. The electrolytic removal process recovers copper ions that can be precipitated and reused, reducing overall material loss.
3Ease of operation
If PMMA polymer is used for graphene transfer, then graphene can be transferred to target substrates, but process time increases due to slow chemical etching
Solution Approach 1:
The patent replaces the chemical etching mechanism with an electrolytic removal mechanism. Instead of using slow chemical etchants to remove the copper substrate, an electrolytic cell applies electrical current to rapidly dissolve the thin copper foil, transferring graphene to the target substrate in a significantly reduced time frame.
Solution Approach 2:
The patent introduces an electrolyte solution as an intermediary medium between the copper substrate and target substrate. The electrolyte enables ionic conduction for electrolytic copper removal and facilitates graphene transfer without requiring organic solvents or polymer materials, accelerating the transfer process.
4Reliability
If expensive polymer materials are used for coating and transfer, then graphene can be supported, but manufacturing cost increases above market competitiveness threshold
Solution Approach 1:
The patent employs a disposable thin copper foil instead of expensive, reusable polymer materials. The ultra-thin copper foil (1-10 micrometers) is inexpensive enough to be used once and then electrolytically removed, eliminating the need for costly PMMA polymer coatings while maintaining graphene support stability during the synthesis and transfer process.
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 approach reduces production costs by minimizing catalyst usage and energy requirements, enabling scalable graphene manufacturing and transfer to point-of-use devices while achieving competitive pricing of $10 per square meter.
Implementation Method 1
electrolytically removing the catalyst film from the support with simultaneous transferring of the graphene to the desired substrate
Implementation Method 2
roll-to-roll electroplating to form a catalyst-coated support for graphene synthesis
Data Source
AI summary
A method of producing a graphene film (22) includes forming a catalyst film (20) on a support (18); forming a graphene film (22) on the catalyst film (20); and electrolytically removing the catalyst film (20) from the support (18). The method may include transferring the graphene film (22) to a substrate (29). A supported graphene film includes a conductive support (18); a catalyst film (20) formed on the conductive support (18) having a thickness in a range of 1 nm to 10 μm, and a graphene film (22) formed on the catalyst film (20).