Graphene production by the thermal release of intrinsic carbon
The present invention generally relates to a process for manufacturing graphene coated surfaces using the intrinsic carbon within a metal.
1. A method of forming graphene, comprising:
(a) applying a vacuum to a furnace, the inside of the furnace comprising:
A. an oxygen scavenger; and,
B. a growth sample, the growth sample, comprising: a carbon-containing metal and a substrate, wherein the carbon-containing metal is in the form of a plurality of seeds that are in contact with the substrate;
(b) introducing a hydrogen-containing gas to the furnace;
(c) heating the inside of the furnace to a temperature and for a time sufficient to initiate graphene formation on the carbon-containing metal;
(d) cooling the furnace; and
(e) removing the seeds from the substrate.
2. The method of claim 1 , wherein the carbon-containing metal is selected from: Fe and Ni.
3. The method of claim 1 , wherein the carbon-containing metal is carbon steel.
4. The method of claim 1 , wherein the carbon-containing metal is 1095 steel.
5. The method of claim 1 , wherein the carbon-containing metal is grey steel.
6. The method of claim 1 , wherein the substrate is selected from: Cu, sapphire, and Ni on sapphire.
7. The method of claim 1 , wherein the substrate is Cu.
8. The method of claim 1 , wherein the substrate is sapphire.
9. The method of claim 1 , wherein the substrate is Ni on sapphire.
10. The method of claim 1 , wherein the oxygen scavenger is Ti sponge.
11. The method of claim 1 , wherein the vacuum applied is ≤10 mTorr.
12. The method of claim 1 , wherein the vacuum applied is 2 mTorr.
13. The method of claim 1 , wherein the hydrogen-containing gas is introduced until the pressure of the furnace is from 20-150 mTorr.
14. The method of claim 1 , wherein the hydrogen-containing gas is a forming gas.
15. The method of claim 1 , wherein the hydrogen-containing gas is 95% Ar/5% H 2 .
16. The method of claim 1 , wherein the hydrogen-containing gas is 95% N 2 /5% H 2 .
17. The method of claim 1 , wherein the furnace is heated to a temperature of from 900-1100° C. for an hour.
18. The method of claim 1 , wherein the furnace is maintained at its highest temperature for 30-60 minutes.