Permeable Junction Roll-to-Roll Graphene Patterning With Lower Resource Use

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Microfabrication processes for electronic devices face sustainability challenges due to high chemical and energy consumption during patterning and transfer stages.

Innovation Solution

A roll-to-roll (R2R) apparatus is developed for continuous production of carbon/graphene-based electronic devices, incorporating a substrate handling module, infiltration module, patterning module, and post-processing module, utilizing a freely moving unwind unit, tension control system, infiltration bath, heater assembly, ablation machine, and control system to achieve uniform and high-quality electronic devices with minimal environmental impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional microfabrication processes are used for patterning and transfer stages, then high manufacturing precision can be achieved, but chemical and energy consumption increases substantially

Engineering Contradiction:

Improvepatterning precisionVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent replaces conventional mechanical lithography systems with a laser-based direct writing system that uses optical energy to deposit carbon materials directly onto substrates. This substitution eliminates the need for expensive photolithography equipment and reduces energy consumption while maintaining manufacturing precision through computer-controlled laser positioning and material deposition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameters of the fabrication process by using laser-induced carbonization instead of photochemical reactions. By controlling laser power, scanning speed, and carbon source delivery parameters, the system achieves precise patterning with lower energy consumption compared to conventional lithography methods.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conventional microfabrication processes are used for patterning and transfer stages, then high manufacturing precision can be achieved, but chemical consumption increases substantially

Engineering Contradiction:

Improvepatterning precisionVSAvoidchemical consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces chemical lithography processes with direct laser carbonization, eliminating the need for photoresist, etchants, and other chemicals. The laser directly carbonizes precursor materials onto the substrate, significantly reducing chemical consumption and waste while maintaining patterning precision through optical control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses disposable carbon source materials that are deposited and then removed, eliminating the need for persistent chemical reagents. The carbonized patterns are created through temporary carbon deposition that can be precisely controlled and removed without leaving chemical residues.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If roll-to-roll continuous production is implemented, then productivity increases, but manufacturing precision control becomes more difficult

Engineering Contradiction:

Improveproduction speedVSAvoidpattern uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent incorporates real-time feedback control systems that monitor laser power, substrate temperature, and material deposition rates during roll-to-roll processing. This feedback enables dynamic adjustment of process parameters to maintain manufacturing precision and pattern uniformity even at high production speeds.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent implements continuous laser scanning and carbon deposition throughout the roll-to-roll process, eliminating stop-start operations. This continuous action maintains consistent thermal and material conditions, ensuring pattern uniformity while maximizing productivity through uninterrupted fabrication.

Inventive Principle:

Principle #20Continuity of useful action

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

The R2R apparatus enables efficient, scalable, and sustainable production of flexible electronic devices with reduced resource consumption and environmental footprint, achieving high-quality patterns and rapid delamination through permeable junctions.

Implementation Method 1

the ablation machine comprises a K40 CO2 laser configured to create conductive carbon/graphene patterns on the flexible substrate such that the K40 CO2 laser is configured to transform cellulose-based material into conductive carbon/graphene patterns on the flexible substrate

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

the heater assembly includes a Joule heater assembled from resistive wire enclosed in high-temperature fiberglass sleeving

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS20260009138A1Permeable Junction-Enhanced Roll-to-Roll Microfabrication for Electronic Devices

Publication Date: 2026.01.08 UNIVERSITY OF CHICAGO

AI summary

The present disclosure relates to a roll-to-roll (R2R) apparatus for continuous production of carbon/graphene-based electronic devices and methods of using a R2R apparatus for continuous production of carbon/graphene-based electronic devices.