Method for transferring a large-area graphene sheet

Patent metadata

Field	Value
Publication number	US-2017210107-A1
Application number	US-201615002440-A
Country	US
Kind code	A1
Filing date	Jan 21, 2016
Priority date	Jan 21, 2016
Publication date	Jul 27, 2017
Grant date	—

Abstract

A method of transferring a graphene sheet comprising one or more layers of graphene formed on a metal film, such as a copper film, coating a surface of a metal or alloy substrate onto a target substrate. The method includes fixedly contacting the graphene sheet with a contacting surface of the target substrate by applying substantially uniform pressure and heat on a layered assembly. The layered assembly comprises the metal or alloy substrate, the graphene sheet, and the target substrate. At least one layer of graphene of the graphene sheet formed on the copper film coating the surface of the metal or alloy substrate is transferred onto the contacting surface of the target substrate by the substantially uniform pressure and heat, and the at least one layer of graphene forms a graphene film on the contacting surface of the target substrate.

First claim

1 . A method of transferring a graphene sheet comprising one or more layers of graphene onto a target substrate, comprising:
fixedly contacting the graphene sheet comprising one or more layers of graphene formed on a copper film coating a surface of a metal or alloy substrate with a contacting surface of the target substrate by applying substantially uniform pressure and heat on a layered assembly comprising the metal or alloy substrate having the surface coated with the copper film, the graphene sheet formed on the copper film, and the target substrate with the contacting surface in contact with the graphene sheet, wherein at least one layer of graphene of the graphene sheet formed on the copper film coating the surface of the metal or alloy substrate is transferred onto the contacting surface of the target substrate by the substantially uniform pressure and heat, and wherein the at least one layer of graphene forms a graphene film on the contacting surface of the target substrate.

2 . The method of claim 1 , wherein the thickness of the copper film coating the surface of the metal or alloy substrate is about 200-800 nm.

3 . The method of claim 1 , wherein the metal or alloy substrate comprises at least one selected from the group consisting of silicon, Ni, Co, Fe, Pt, Au, Al, Cr, Cu, Mg, Mn, Mo, Rh, Si, Ta, Ti, W, U, V, Zr, brass, bronze, white brass, stainless steel, and Ge.

4 . The method of claim 1 , wherein the metal or alloy substrate has a roll shape, a foil shape, a tube shape, a plate shape, a sheet shape or a wire shape.

5 . The method of claim 1 , wherein the graphene sheet comprising one or more layers of graphene formed on the copper film coating the surface of the metal or alloy substrate is formed by supplying heat and a reaction gas comprising a carbon source to the copper film coating the surface of the metal or alloy substrate for a reaction to grow the one or more layers of graphene of the graphene sheet on the copper film.

6 . The method of claim 1 , wherein the target substrate comprises at least one selected from the group consisting of a polymer, a polymer mixture, a plastic, a rubber, a glass, a metal, Si, and SiO 2 .

7 . The method of claim 1 , wherein the substantially uniform pressure is at least 5 psi.

8 . The method of claim 1 , wherein the substantially uniform heat applied on the layered assembly heats the layered assembly to a temperature of at least 180° C.

9 . A method of transferring a graphene sheet comprising one or more layers of graphene onto a sheet of a flexible target substrate, comprising:
fixedly contacting the graphene sheet comprising one or more layers of graphene formed on a copper film coating a surface of a metal or alloy substrate foil with a contacting surface of the sheet of the flexible target substrate by subjecting a layered assembly comprising the metal or alloy substrate foil having the surface coated with the copper film, the graphene sheet formed on the copper film, and the sheet of the flexible target substrate with the contacting surface in contact with the graphene sheet to at least one blank page printing operation in a printing device, wherein the printing device comprises at least one fuser unit comprising at least one heat roller and at least one pressure roller, wherein the at least one fuser unit applies substantially uniform pressure and heat by the at least one pressure roller and the at least one heat roller on the layered assembly during the at least one blank page printing operation, wherein at least one layer of graphene of the graphene sheet formed on the copper film coating the surface of the metal or alloy substrate foil is transferred onto the contacting surface of the sheet of the flexible target substrate by the substantially uniform pressure and heat, and wherein the at least one layer of graphene forms a graphene film on the contacting surface of the sheet of the flexible target substrate.

10 . The method of claim 9 , wherein the metal or alloy substrate foil comprises at least one selected from the group consisting of silicon, Ni, Co, Fe, Pt, Au, Al, Cr, Cu, Mg, Mn, Mo, Rh, Si, Ta, Ti, W, U, V, Zr, brass, bronze, white brass, stainless steel, and Ge.

11 . The method of claim 9 , wherein the sheet of the flexible target substrate comprises at least one selected from the group consisting of polyethylene terephthalate, polyimide, cellulose acetate, glass, polyethylene naphthalate, polycarbonate, plastic, and rubber.

12 . The method of claim 9 , wherein one layer of graphene of the graphene sheet formed on the copper film coating the surface of the metal or alloy substrate foil is transferred onto the contacting surface of the sheet of the flexible target substrate by the substantially uniform pressure and heat, and
wherein the one layer of graphene forms a monolayered graphene film on the contacting surface of the sheet of the flexible target substrate.

13 . The method of claim 12 , wherein the monolayered graphene film on the contacting surface of the sheet of the flexible target substrate has an optical transmittance of at least 88% when subjected to a light with a wavelength of 300-2000 nm.

14 . The method of claim 9 , wherein the graphene film on the contacting surface of the sheet of the flexible target substrate has a resistance of no greater than 250 Ω/cm 2 by a four probe Van der Pauw method.

15 . The method of claim 9 , further comprising stretching the graphene film on the contacting surface of the sheet of the flexible target substrate to form an elongated graphene film,
wherein the elongated graphene film has a dimension that is longer, but no greater than about 20% longer than the graphene film before the stretching, and wherein the elongated graphene film has a resistance that is the same as, or different from, the resistance of the graphene film before the stretching, but no more than about 10% different from the resistance of the graphene film before the stretching.

16 . The method of claim 9 , further comprising stretching the graphene film on the contacting surface of the sheet of the flexible target substrate to form an elongated graphene film,
wherein the elongated graphene film has a dimension that is longer, but no greater than 20% longer than the graphene film before the stretching, and then relaxing the elongated graphene film from the stretching to form a relaxed graphene film, wherein the relaxed graphene film has a resistance that is the same as, or different from, the resistance of the graphene film before the stretching, but no more than about 10% different from the resistance of the graphene film before the stretching.

17 . The method of claim 9 , further comprising subjecting the graphene film on the contacting surface of the sheet of the flexible target substrate to a bending strain of no greater than about 30% to form a bent graphene film,
wherein the bent graphene film has a resistance that is the same as, or different from, the resistance of the graphene film before being subjected to the bending strain, but no more than about 10% different from the resistance of the graphene film before being subjected to the bending strain.

18 . The method of claim 9 , further comprising subjecting the graphene film on the contacting surface of the sheet of the flexible target substrate to a bending strain of no greater than about 30% to form a bent graphene film, and then
relaxing the bent graphene film from the bending strain to form a relaxed graphene film, wherein the relaxed graphene film has a resistance that is the same

Assignees

• Univ King Abdulaziz

Inventors

• Al-Hazmi Farag Saeed Marshoud
• Al-Ghamdi Ahmed Abdullah Salem
• ELSAYED Waleed Elsayed Mahmoud

Classifications

• B32B2313/04

  Carbon · CPC title

• B32B18/00

  Layered products essentially comprising ceramics, e.g. refractory products · CPC title

• B32B2311/12

  Copper · CPC title

• B32B37/025 Primary

  Transfer laminating · CPC title

• B32B15/04

  comprising metal as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042)} · CPC title