Subsurface Laser Carbon Foam for Thick, Adherent 3D Nanostructures

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Solution Overview

Problem

Existing methods for producing 3D graphene, such as laser-induced graphene, result in materials that are brittle, have limited thickness, and poor adhesion to substrates, making them unsuitable for many applications.

Innovation Solution

A Dual Laser process is employed to convert a sub-surface region of a carbon precursor material to carbon foam, using two separate lasers to create a disorganized, amorphous non-graphene material above the carbon foam, which is then ablated to expose the underlying carbon foam, resulting in a hydrophilic and highly porous structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If laser-induced graphene production is used to create 3D graphene, then the material can be produced with a simple process, but the resulting graphene is brittle and has poor adhesion to substrates

Engineering Contradiction:

Improvesimplicity of production processVSAvoidadhesion to substrate

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent introduces an intermediary layer between the carbon precursor and the substrate. This intermediate layer, formed by laser irradiation, acts as a bonding interface that improves adhesion between the resulting carbon foam and the substrate, resolving the poor adhesion problem while maintaining the simplicity of the laser-based production process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent modifies the laser irradiation parameters (wavelength, power, scanning speed, focal position) to control the formation process. By optimizing these parameters, the process produces carbon foam with improved mechanical properties and adhesion while keeping the manufacturing process simple and direct

Inventive Principle:

Principle #35Parameter changes

2Productivity

If laser-induced graphene production is used, then the process can be performed rapidly, but the thickness of the produced graphene is limited to less than 50 μm

Engineering Contradiction:

Improveproduction speedVSAvoidthickness of graphene

Core Design Contradiction:

ProductivityVSLength of stationary object

Solution Approach 1:

The patent transitions from producing thin 2D graphene layers to creating thick 3D carbon foam structures. By focusing the laser beam and controlling the irradiation process in the depth dimension, the method produces carbon foam with thickness exceeding 50 μm while maintaining rapid production speeds through the direct laser writing approach

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If conventional laser-induced graphene is produced, then the material forms at the surface, but the surface graphene is brittle and may flake off the substrate

Engineering Contradiction:

Improvedirect surface formationVSAvoidstructural stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of forming graphene directly at the surface and hoping for adhesion, the patent inverts the approach by creating carbon foam that grows into the substrate or forms an interlocking structure. This inverted formation method ensures structural stability and prevents flaking while maintaining the ease of direct laser writing

Inventive Principle:

Principle #13The other way round (Inversion)

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 produces carbon foam with enhanced wettability, anti-fouling properties, and improved electrochemical performance, suitable for biosensors and supercapacitors, with higher sensitivity and efficiency compared to conventional methods.

Implementation Method 1

using a first laser beam to irradiate an encapsulated or sub-surface region of a carbon precursor material below a surface of the material, to create carbon foam in that sub-surface region

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

irradiating a sub-surface region of a carbon precursor material, parameters of the laser beam being selected to create a carbon foam in that sub-surface region

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Implementation Method 3

using a second laser beam to remove or ablate material sitting above the carbon foam, to expose at least some of the carbon foam

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12497295B2Laser-induced carbon nanostructures

Publication Date: 2025.12.16 INTEGRATED GRAPHENE HOLDING LIMITED

AI summary

A method of manufacturing a carbon nanostructure, such as a carbon foam material, is disclosed. The method comprises the steps of: (a) using a first laser beam to irradiate an encapsulated or sub-surface region of a carbon pre-cursor material below a surface of the material, to create carbon foam in that sub-surface region, and a disorganised, amorphous non-graphene material above the carbon foam, and then (b) using a second laser beam to remove or ablate the disorganised, amorphous non-graphene material sitting above the carbon foam, to expose at least some of the carbon foam. The resultant carbon foam material shows a significant D peak; the 2D peak is significantly less than the G peak; and the peak D: peak G ratio is significantly above zero. In appearance and Raman signature, it appears similar to a carbon nano-onion material. It can be used in biosensors, supercapacitors and pseudo-capacitors.