Large area deposition of graphene on substrates, and products including the same

• US 20110143045A1
• Filed: 12/15/2009
• Published: 06/16/2011
• Est. Priority Date: 12/15/2009
• Status: Active Grant

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Veerasamy, Vijayen S.
• Granted Patent: US 8,808,810 B2
• Time in Patent Office: Days
• US Class Current: 427/495
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 32/188 by epitaxial growth
• CPC Class Codes: C01B 32/194 After-treatment
• CPC Class Codes: C01P 2004/24 Nanoplates, i.e. plate-like particles with a thickness from 1-100 nanometer
• CPC Class Codes: C03C 17/28 with organic material C03C17/34, C03C17/44 take precedence
• CPC Class Codes: C03C 17/42 at least one coating of an organic material and at least one non-metal coating

Abstract

Certain example embodiments of this invention relate to the use of graphene as a transparent conductive coating (TCC). A substrate having a surface to be coated is provided. A self-assembled monolayer (SAM) template is disposed on the surface to be coated. A precursor comprising a precursor molecule is provided, with the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) and discotic molecule. The precursor is dissolved to form a solution. The solution is applied to the substrate having the SAM template disposed thereon. The precursor molecule is photochemically attached to the SAM template. The substrate is heated to at least 450 degrees C. to form a graphene-inclusive film. Advantageously, the graphene-inclusive film may be provided directly on the substrate, e.g., without the need for a liftoff process.

Claims

1. A method of making a coated article, the method comprising:

providing a substrate having a surface to be coated;

disposing a self-assembled monolayer (SAM) template on the surface to be coated;

providing a precursor comprising a precursor molecule, the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) and discotic molecule;

dissolving the precursor to form a solution;

applying the solution to the substrate having the SAM template disposed thereon;

photochemically attaching the precursor molecule to the SAM template; and

heating the substrate to at least 450 degrees C. to form a graphene-inclusive film.

2. The method of claim 1, wherein the substrate is a glass substrate.

3. The method of claim 1, wherein the substrate is a silicon wafer.

4. The method of claim 1, further comprising providing a layer comprising silicon oxide on the surface to be coated prior to the disposing of the SAM template.

5. The method of claim 1, wherein the SAM template is a silane-benzophenone derivative.

6. The method of claim 5, wherein the SAM template is chlorosilane benzophenone (CSBP).

7. The method of claim 1, wherein the SAM template and/or the precursor molecule comprise(s) one or more alkyl groups.

8. The method of claim 1, wherein the precursor molecule is C96 and/or HBC.

9. The method of claim 1, further comprising purifying the solution via column chromatography.

10. The method of claim 9, further comprising preparing the solution in chloroform and/or dodecane.

11. The method of claim 1, wherein the c-axis of precursor molecule is substantially perpendicular to substrate prior to and/or following the photochemical attaching.

12. The method of claim 1, wherein the photochemical attaching includes irradiating UV energy towards the substrate.

13. The method of claim 12, wherein the wavelength of the UV energy is between 320-380 nm.

14. The method of claim 1, wherein said heating is performed in a vacuum.

15. The method of claim 1, wherein said heating is performed in an environment comprising inert gas.

16. The method of claim 15, wherein said heating is performed in an environment comprising Ar and C₂H₂ gasses.

17. A method of making a coated article, the method comprising:

providing a substrate having a surface to be coated;

disposing a self-assembled monolayer (SAM) template on the surface to be coated;

applying a solution to the substrate having the SAM template disposed thereon, the solution comprising a precursor including a precursor molecule, the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) molecule;

attaching the precursor molecule to the SAM template by irradiating UV energy thereon; and

heating the substrate to at least 450 degrees C. to form a graphene-inclusive film,

wherein the SAM template and/or the precursor molecule comprise(s) one or more alkyl groups to help ensure that the c-axis of precursor molecule is substantially perpendicular to substrate prior to and/or following the photochemical attaching.

18. The method of claim 17, further comprising providing a layer comprising silicon oxide on the surface to be coated prior to the disposing of the SAM template.

19. The method of claim 17, wherein the SAM template is a silane-benzophenone derivative.

20. The method of claim 17, wherein the precursor molecule is C96 and/or HBC.

21. The method of claim 17, wherein said heating is performed in a vacuum.

22. The method of claim 17, wherein said heating is performed in an environment comprising inert gas.

23. A method of making an electronic device, the method comprising:

providing a substrate having a surface to be coated;

disposing a self-assembled monolayer (SAM) template on the surface to be coated;

providing a precursor comprising a precursor molecule, the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) and discotic molecule;

dissolving the precursor to form a solution;

applying the solution to the substrate having the SAM template disposed thereon;

photochemically attaching the precursor molecule to the SAM template;

heating the substrate to at least 450 degrees C. to form a graphene-inclusive film on the substrate; and

building the substrate with the graphene-inclusive film into the electronic device.

24. A method of making an electronic device, the method comprising:

providing a substrate having a surface to be coated;

disposing a self-assembled monolayer (SAM) template on the surface to be coated;

applying a solution to the substrate having the SAM template disposed thereon, the solution comprising a precursor including a precursor molecule, the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) molecule;

attaching the precursor molecule to the SAM template by irradiating UV energy thereon;

heating the substrate to at least 450 degrees C. to form a graphene-inclusive film; and

building the substrate with the graphene-inclusive film into the electronic device,

wherein the SAM template and/or the precursor molecule comprise(s) one or more alkyl groups to help ensure that the c-axis of precursor molecule is substantially perpendicular to substrate prior to and/or following the photochemical attaching.

25. A method of making a coated article, the method comprising:

providing a substrate having a surface to be coated;

disposing a monolayer template on the surface to be coated;

providing a gaseous stream comprising a carrier gas and a precursor molecule proximate to the substrate having the monolayer template disposed thereon, the precursor molecule being a polycyclic aromatic hydrocarbon (PAH) molecule;

attaching the precursor molecule to the monolayer template by irradiating UV energy thereon; and

heating the substrate with the monolayer template and the precursor molecule to form a graphene-inclusive film,

wherein the monolayer template and/or the precursor molecule comprise(s) one or more alkyl groups to help ensure that the c-axis of precursor molecule is substantially perpendicular to substrate prior to and/or following the photochemical attaching.