Graphene Formation via Organic Monolayer Carbonization
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Solution Overview
Problem
Current methods for producing graphene are cumbersome and limited to small-scale production, making them unsuitable for large-scale applications due to their complexity and inefficiency.
Innovation Solution
A method involving patterning an organic material monolayer on a substrate, followed by the application of thermal energy to carbonize it, forming a patterned layer of graphene, which can be enhanced by using a localized energy beam or a sandwich configuration with heated substrates to improve efficiency and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical exfoliation or evaporative methods are used to produce graphene, then graphene can be obtained with unique properties, but the production is limited to small scale and the process is cumbersome and complicated
Solution Approach 1:
The process segments graphene production into distinct stages: (1) depositing organic material monolayer on substrate, (2) patterning the monolayer to desired geometry, and (3) carbonizing the patterned layer to form graphene. This segmentation enables each stage to be optimized independently, facilitating scalable production while maintaining quality.
Solution Approach 2:
The patent applies preliminary action by first depositing and patterning the organic material monolayer before carbonization. This pre-patterned organic layer serves as a template that guides subsequent graphene formation, enabling precise geometric control and scalable production without compromising the unique properties of graphene.
2Manufacturing precision
If thermal energy is applied to carbonize organic material monolayer, then patterned graphene layer is formed, but evaporation of organic material may occur reducing production efficiency
Solution Approach 1:
The patent employs an inert atmosphere during the carbonization process to prevent evaporation of the organic material monolayer. This inert environment suppresses unwanted thermal effects while allowing controlled carbonization, thereby improving production efficiency and reducing material loss.
3Reliability
If conventional production methods are used, then graphene can be produced for research purposes, but the methods are not suitable for large-scale applications due to complexity
Solution Approach 1:
The patent employs a universal substrate approach that can accommodate various organic materials and patterning methods. The same basic process framework (deposit-pattern-carbonize) works for different materials and geometries, reducing process complexity while enabling large-scale production of graphene with consistent properties.
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 allows for the scalable production of graphene with reduced evaporation and improved carbonization efficiency, enabling the formation of patterned graphene layers suitable for various applications, including electronics and energy storage devices.
Implementation Method 1
supplying energy to at least a portion of an organic material monolayer disposed on a substrate, the energy being a localized beam of energy, the energy being sufficient to carbonize the at least a portion of the monolayer exposed thereto to form a layer of graphene on the substrate
Implementation Method 2
supplying thermal energy to the patterned organic material monolayer, the thermal energy being sufficient to carbonize the monolayer to form a patterned layer of graphene on the substrate
Implementation Method 3
The thermal energy may be supplied by a hot plate, or by a heating element of any of a furnace, a kiln, and an oven
Implementation Method 4
The patterning may be carried out by ablation using a localized beam of energy. The localized beam of energy may be any of a laser beam, a maser beam, and an electron beam
Implementation Method 5
The non-planar surface may be heated, and wherein the patterning is carried out by evaporating portions of the organic material monolayer contacting the stamp
Data Source
AI summary
A method of forming graphene comprises patterning an organic material monolayer disposed on a first substrate to yield a patterned organic material monolayer, and supplying thermal energy to the patterned organic material monolayer. The thermal energy is sufficient to carbonize the monolayer to form a patterned layer of graphene on said substrate.