Graphene Production via Seedlac Vapor Deposition
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Solution Overview
Problem
Current graphene production methods face limitations such as the need for specific substrates, precise control of processing parameters, and are not economically viable, hindering the commercialization of graphene-based products.
Innovation Solution
A process involving heating a substrate and contacting seedlac vapors with it, followed by cooling, to produce graphene without the need for specific substrates or precise control, allowing for large area coverage and commercial viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If Chemical vapour deposition (CVD) process is used for production of graphene, then large surface coverage is achieved, but precise control on processing parameters and catalytic need at lower temperature are required
Solution Approach 1:
The patent changes the temperature parameter from low temperature (CVD) to high temperature (800-1000°C), which eliminates the need for precise parameter control and catalytic substrates. This parameter change transforms the process from requiring strict control to being more tolerant and simpler to implement.
Solution Approach 2:
The patent uses a simple hydrocarbon source that can be introduced directly without requiring expensive catalytic substrates like nickel or copper. The process uses readily available materials and simpler equipment, making it more economically viable and easier to operate.
2Reliability
If mechanical exfoliation or plasma treatment methods are used, then graphene can be prepared, but production is limited to particular substrates and controlled atmosphere is required
Solution Approach 1:
The patent creates a universal process that works on various substrates including conductive and non-conductive materials. The high temperature hydrocarbon deposition method is not limited to specific substrate types, making it applicable to a broad range of materials and eliminating the need for controlled atmosphere.
Solution Approach 2:
The patent eliminates the requirement for controlled or inert atmosphere by conducting the process in ambient conditions. The high temperature deposition of hydrocarbons forms stable graphene structures that do not require protective atmospheres, simplifying the process setup and operation.
3Reliability
If known graphene production processes are used, then graphene can be produced, but the processes are not economical
Solution Approach 1:
The patent uses inexpensive hydrocarbon sources and eliminates the need for expensive catalytic substrates and complex equipment. The process employs readily available materials and simpler manufacturing setup, significantly reducing production costs while maintaining reliable graphene production.
Solution Approach 2:
The process allows graphene to form directly through spontaneous hydrocarbon deposition at high temperature without requiring additional catalytic agents or complex process steps. The system uses the energy input to directly convert hydrocarbons to graphene on the substrate surface, eliminating intermediate steps and reducing manufacturing 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
The process enables the production of impermeable, oxidation-resistant, and hydrophobic graphene on various substrates, including conductive and non-conductive materials, with improved corrosion resistance and economic feasibility.
Implementation Method 1
heating a substrate and at least one feeder; contacting vapours of seedlac with the substrate
Implementation Method 2
cooling the substrate to produce the graphene
Data Source
AI summary
The present disclosure relates to a process for producing graphene, wherein the process is simple and economical. In the said process the substrate is contacted with vaporized seedlac to produce graphene on a substrate including but not limited to conductive material and non-conductive material. The disclosure further relates to a graphene which is impermeable to ions and molecules, resistant to oxidation and is hydrophobic. The disclosure furthermore relates to a substrate comprising graphene, said substrate is resistant to corrosion, resistant to oxidation and is hydrophobic.