Addressing Challenges in CVD Graphene Transfer Processes

Aug 16, 2023 | Knowledge Center

Chemical Vapor Deposition (CVD) graphene transfer processes are critical for the industrial application and scalability of graphene technology. However, the transfer of large-area CVD graphene films presents several challenges that need to be addressed to unlock the full potential of graphene for various industrial applications^1,2.

Challenges in CVD Graphene Transfer

Batch Scale Limitations

Current transfer methods, such as oxidative decoupling and wet etch transfer, are often performed in batch processes. These methods are time-consuming and limit the scalability of the graphene transfer process³.

Contaminant-Free Transfer

Obtaining largely contaminant-free CVD graphene is a significant challenge. The transfer process can introduce defects and tears on the graphene surface, affecting its quality⁴.

High Operating and Input Costs

The transfer process for CVD graphene can be costly due to the equipment, materials, and chemicals involved⁵.

Use of Harsh Chemicals

Some transfer methods require the use of harsh chemicals, which can be environmentally unfriendly and pose safety concerns⁶.

Successful Separation from the Substrate

While it is possible to create high-quality graphene on a substrate using CVD, successful “defect-free” separation of graphene from its growth substrate has been challenging.

Contaminant Removal

Removing contaminants from transferred CVD graphene is a significant challenge. The complete removal of support materials without contaminating the graphene is crucial².

Direct Growth on Insulating Substrates

Achieving direct growth on insulating substrates is a challenge in CVD graphene synthesis. This is important for expanding the range of potential applications for graphene³.

Large-Area Transfer

Transferring large-area graphene films with cleanliness and uniformity is another challenge. Both wet and dry transfer methods have their own advantages and challenges⁴.

Potential Solutions to CVD Graphene Transfer Challenges

Developing Roll-to-Roll Transfer Methods

Roll-to-roll transfer methods can potentially increase efficiency and scalability in CVD graphene transfer processes⁶.

Improving Transfer Techniques

Optimizing the transfer process parameters, such as temperature, pressure, and adhesion methods, can help minimize defects and tears on the graphene surface².

Reducing Chemical-Intensive Processes

Finding alternative methods that reduce the reliance on harsh chemicals can make the transfer process more environmentally friendly³.

General Graphene’s Novel Approach to CVD Graphene Transfer

General Graphene has made significant advancements in both its roll-to-roll CVD graphene production and transfer technologies to directly address the challenges of producing mass volumes of CVD graphene films cost-effectively at reproducible qualities tailored for specific end applications³.

Towards the end of 2022, we integrated an inline coating system to GG 3.0, the third iteration of our proprietary roll-to-roll CVD production system. This integrated system enables us to coat a variety of thin polymer films onto a roll of CVD graphene-on-catalyst substrate. The thin polymer film coatings can also be cured and laminated before the resulting graphene-on-polymer output leaves the GG 3.0 production³.

The output is fed directly into our Roll-to-Roll CVD Graphene Transfer system, where the graphene-on-polymer is separated from the surface of the catalyst material. The system is capable of transferring several square meters of graphene onto a variety of polymeric films and has shown significant potential in helping facilitate large-area roll-to-roll transfers with minimal transfer induced defects³.

Additionally, this system has a very small chemical footprint which thereby makes it easier and less expensive to implement at scale. It can successfully reuse copper foil – its primary catalyst material – once the graphene-on-polymer has been separated from it³.

By addressing the challenges associated with traditional transfer processes and developing novel technology that directly addresses historical bottlenecks towards commercialization, General Graphene successfully demonstrates a path towards the industrial-scale manufacturing of large-area roll-to-roll CVD graphene films transferred to polymers.