Graphene Fabrication Using Release Layer Discontinuity
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Solution Overview
Problem
Current methods for forming electronic devices using two-dimensional materials like graphene face challenges in achieving high-quality charge transfer characteristics and minimizing contamination and defects, particularly in forming field effect transistors and other electronic components.
Innovation Solution
A method involving the formation of a layer of two-dimensional material on a release layer, followed by the deposition of electrodes and a mouldable polymer, with a second release layer creating a discontinuity between the polymer and the material to prevent contamination, and optionally using nitrogen or inert materials within this gap to protect the graphene, allowing for the formation of high-quality electronic components such as field effect transistors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous contact between mouldable polymer and two-dimensional material is maintained during fabrication, then structural support is provided, but contamination and defects occur in the two-dimensional material
Solution Approach 1:
The patent introduces a discontinuity (gap) that segments the interface between the mouldable polymer and the two-dimensional material, separating them to prevent contamination while maintaining structural integrity through alternative support mechanisms
Solution Approach 2:
The discontinuity acts as an intermediary space between the polymer and two-dimensional material, preventing direct contact and thus eliminating the contamination pathway while still allowing the device to function
2Object-affected harmful factors
If release layers are removed to create discontinuity, then contamination is prevented, but structural support is reduced
Solution Approach 1:
The patent extracts (removes) the release layers to create the discontinuity, taking out the source of potential contamination while the structural support function is transferred to other components of the device architecture
Solution Approach 2:
The discontinuity creates a localized region of separation specifically where contamination would occur, while other regions maintain their structural support functions, achieving local optimization without compromising overall device integrity
3Ease of manufacture
If two-dimensional material is formed directly on substrate without release layers, then fabrication is simplified, but charge transfer characteristics deteriorate
Solution Approach 1:
The patent applies preliminary action by forming the two-dimensional material on a release layer before final device assembly, allowing the material to be prepared in advance under optimal conditions and then transferred to the final structure where it can achieve superior charge transfer characteristics
Data Source
AI summary
A method and apparatus, the method comprising: forming a layer of two dimensional material (23), in particular graphene, on a first release layer; forming, possibly a (gate) insulating layer (35), and at least two, preferably three, electrodes (25); forming a second release layer overlaying at least a portion of the layer of two dimensional material; providing a mouldable polymer (24, 26, 28) overlaying the at least two electrodes and the second release layer; and removing the first and second release layers to provide a cavity (29) between the mouldable polymer (26) and the layer of two dimensional material (23).