Transfer-free method for producing graphene thin film
11124870 · 2021-09-21
Assignee
Inventors
Cpc classification
H01G4/1254
ELECTRICITY
H01G4/33
ELECTRICITY
H01B1/04
ELECTRICITY
International classification
H01G4/33
ELECTRICITY
H05K1/16
ELECTRICITY
H01B13/00
ELECTRICITY
C23C14/04
CHEMISTRY; METALLURGY
C23C16/04
CHEMISTRY; METALLURGY
H01B1/04
ELECTRICITY
Abstract
The present invention relates to a transfer-free method for producing a graphene thin film, which may form a high-quality graphene layer having excellent crystallinity on a substrate without a transfer process, and to a method of fabricating a device using the transfer-free method. More specifically, the present invention relates to a transfer-free method for producing a graphene thin film and a method for fabricating a device using the transfer-free method, the methods including the steps of: (A) forming a titanium buffer layer on a target substrate; and (B) growing a graphene thin film on the titanium buffer layer, wherein process are performed in an oxygen-free atmosphere throughout the steps (A) to (B).
Claims
1. A transfer-free method for producing a transparent electrode comprising a graphene thin film, comprising the steps of: (A) forming a titanium buffer layer on a target substrate, the transmittance of the titanium buffer layer formed substrate at 550 nm being decreased by 0.4±0.05% compared to that of the target substrate itself; and (B) growing a graphene thin film on the titanium buffer layer, wherein entire steps throughout (A) to (B) are performed in-situ in the same system, and thus performed in an oxygen-free atmosphere in which titanium is not oxidized, I.sub.D/I.sub.G of the graphene thin film is 0.01±0.01, and the graphene thin film is made of monolayer graphene, wherein the transmittance of graphene thin film formed substrate at 550 nm being 97.4±1% relative to the titanium buffer layer formed substrate.
2. The transfer-free method for producing a transparent electrode of claim 1, wherein the steps of forming the titanium buffer layer and the graphene thin film are repeated after step (B).
3. The transfer-free method for producing a transparent electrode of claim 1, wherein the steps are performed at 400° C. or below.
4. The transfer-free method for producing a transparent electrode of claim 1, wherein the forming of the titanium buffer layer in step (A) is performed by a method selected from the group consisting of sputtering, atomic layer deposition (ALD), plasma-enhanced atomic layer deposition (PE-ALD), thermal evaporation, thermal oxidation, e-beam evaporation, molecular beam epitaxy (MBE), pulsed laser deposition (PLD), chemical vapor deposition (CVD), a sol-gel method, and combinations thereof, and the growing of the graphene thin film in step (B) is performed by a chemical vapor deposition method selected from the group consisting of plasma-enhanced chemical vapor deposition (PECVD), rapid thermal chemical vapor deposition (RTCVD), inductively coupled plasma-chemical vapor deposition (ICP-CVD), low-pressure chemical vapor deposition (LPCVD), atmospheric pressure chemical vapor deposition (APCVD), metal organic chemical vapor deposition (MOCVD), atomic layer deposition (ALD), plasma-enhanced atomic layer deposition (PE-ALD), and combinations thereof.
5. The transfer-free method for producing a transparent electrode of claim 1, wherein the titanium buffer layer has a thickness of 10 to 20 nm.
6. The transfer-free method for producing a transparent electrode of claim 1, wherein the target substrate is made of glass, SiO2, or a synthetic resin containing an oxygen atom in its structure.
7. The transfer-free method for producing a transparent electrode of claim 2, wherein the steps are performed at 400° C. or below.
8. The transfer-free method for producing a transparent electrode of claim 2, wherein the forming of the titanium buffer layer in step (A) is performed by a method selected from the group consisting of sputtering, atomic layer deposition (ALD), plasma-enhanced atomic layer deposition (PE-ALD), thermal evaporation, thermal oxidation, e-beam evaporation, molecular beam epitaxy (MBE), pulsed laser deposition (PLD), chemical vapor deposition (CVD), a sol-gel method, and combinations thereof, and the growing of the graphene thin film in step (B) is performed by a chemical vapor deposition method selected from the group consisting of plasma-enhanced chemical vapor deposition (PECVD), rapid thermal chemical vapor deposition (RTCVD), inductively coupled plasma-chemical vapor deposition (ICP-CVD), low-pressure chemical vapor deposition (LPCVD), atmospheric pressure chemical vapor deposition (APCVD), metal organic chemical vapor deposition (MOCVD), atomic layer deposition (ALD), plasma-enhanced atomic layer deposition (PE-ALD), and combinations thereof.
9. The transfer-free method for producing a transparent electrode of claim 2, wherein the titanium buffer layer has a thickness of 10 to 20 nm.
10. The transfer-free method for producing a transparent electrode of claim 2, wherein the target substrate is made of glass, SiO.sub.2, or a synthetic resin containing an oxygen atom in its structure.
11. A transfer-free method for fabricating a transparent electronic device comprising a graphene thin film, the method comprising the steps of: (A) forming a titanium buffer layer on a target substrate, the transmittance of the titanium buffer layer formed substrate at 550 nm being decreased by 0.4±0.05% compared to that of the target substrate itself; (B) forming a graphene thin film on the titanium buffer layer, wherein entire steps throughout (A) to (B) are performed in-situ in the same system, and thus performed in an oxygen-free atmosphere in which titanium is not oxidized, I.sub.D/I.sub.G of the graphene thin film is 0.01±0.01, and the graphene thin film is made of monolayer graphene, wherein the transmittance of graphene thin film formed substrate at 550 nm being 97.4±1% relative to the titanium buffer layer formed substrate; and (C) fabricating the electrical device by using the target substrate.
12. The transfer-free method of claim 11, further comprising, before step (A) or (B), a step of forming a masking pattern having a predetermined shape.
13. The transfer-free method of claim 11, wherein steps (A) and (B) are all performed at 400° C. or below.
14. The transfer-free method of claim 12, wherein steps (A) and (B) are all performed at 400° C. or below.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(12) The present invention is characterized in that (1) it is a “transfer-free” method in which a buffer layer does not need to be removed, because the mechanical, electrical and optical properties of a substrate or a graphene layer are not impaired by the buffer layer, and (2) a flexible device/transparent electrode can be fabricated using a target substrate made of a “flexible” polymer material, because a graphene layer is deposited with high quality even at low temperatures.
(13) Hereinafter, the present invention will be described in further detail with reference to examples. It is to be understood, however, that these examples are for illustrative purposes only and are not intended to limit or change the scope of the present invention. In addition, those skilled in the art will appreciate that various modifications and alterations are possible based on this illustration, without departing from the scope and spirit of the invention.
(14) In the following Examples, for graphene production at various temperatures, considering the temperature characteristics of substrates, a target substrate made of SiO.sub.2 (250 nm)/Si (001) or glass was applied at high temperatures, and a target substrate made of PET was applied otherwise.
(15) In the Examples, a prepared graphene/Ti/substrate was taken out of a system, and then provided for various quality tests. At this time, the graphene/Ti/substrate exposed to the atmosphere was substantially converted to a graphene/TiO.sub.2/substrate due to rapid oxidation of Ti. However, hereinafter, the graphene/TiO.sub.2/substrate oxidized by exposure to the atmosphere will be referred to as “graphene/Ti/substrate” for convenience.
(16) In the Examples, the maximum size of the prepared target substrate was 4×4 cm.sup.2 due to the limitation of the system, and a high-quality graphene thin film could also be grown to this size. However, this size limitation is due to the size limitation of the chamber and components used in the Examples, and thus when the target substrate is prepared using a system having an increased size, a graphene thin film can, of course, be grown to a larger size.
EXAMPLES
Example 1: Deposition of Titanium Buffer Layer
(17) On each of SiO.sub.2 (250 nm)/Si (001), Eagle glass (700 μm) and PET (130 μm) target substrates, a 10-nm titanium buffer layer was deposited using a 2-inch-diameter metal target (purity: 99.99%) by DC sputtering at room temperature under the following conditions: DC power of 20 W; working pressure of 0.4 Pa; and deposition time of 3 minutes. A previous experiment indicated that when the thickness of a deposited titanium buffer layer was thinner than 10 nm, the deposited thickness was not uniform (data not shown).
(18) The thickness of the titanium buffer layer was measured by TEM cross-section imaging, the sheet resistance and transmittance thereof were measured using a four-point probe and a UV-vis spectrometer, respectively. The surface roughness of the titanium buffer layer annealed at various temperatures in a hydrogen atmosphere was measured using AFM (MFP-3D-BIO, Asylum Research) at room temperature in order to examine the thermal stability thereof.
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(20) The surface roughness or height of the titanium buffer layer was hardly affected by annealing (
(21)
(22) For the Ti/PET target substrate annealed at 150° C., the transmittance was hardly changed by deposition or annealing of the titanium buffer layer (see the inset in
(23) Regarding sheet resistance, the titanium buffer layer deposited on the target glass substrate showed a sheet resistance similar to that of the target substrate itself, and no great change was observed even when the titanium buffer layer was annealed at 400° C. in a hydrogen atmosphere (
(24) In addition, in order to examine whether a source material used for graphene growth would affect the titanium buffer layer, a titanium buffer layer was formed on a glass target substrate, and then annealed in a CH.sub.4 gas atmosphere, whether the surface roughness, light transmittance and sheet resistance of the target substrate would change was observed. As a result, even when the titanium buffer layer was annealed at 400° C. or 900° C. for 2 hours, changes in the surface properties (surface roughness, light transmittance and sheet resistance) of the target substrate were not observed (data not shown).
Comparative Example 1: Deposition of Other Metal Buffer Layers and Graphene Formation
(25) Each of 10-nm-thick Ni and Cu thin layers was formed on a glass substrate under the same conditions described in Example 1.
(26) When the nickel and copper thin layers on the glass target substrates were annealed at 150° C. or 600° C. in a hydrogen atmosphere, the surface roughness or transmittance greatly changed (see
(27) Furthermore, according to the same method described in Example 2 below, graphene growth on each of Ni/glass and Cu/glass substrates at 150° C. was attempted. Next, whether a graphene layer would be formed was analyzed using Raman spectra. As a result, as can be seen in
Comparative Example 2: Growth of Graphene by Conventional Chemical Vapor Deposition Using Ex-Situ Method
(28) According to the same procedures as those in a conventional method of forming a copper or nickel buffer layer by a sputtering process, the three target substrates, on which the titanium buffer layer was formed by the method of Example 1, were taken out of the sputtering system and immediately transferred into a 3-zone furnace (
(29) Specifically, a titanium buffer layer was deposited on each target substrate in a sputtering system, and then each target substrate was transferred into a chamber for chemical vapor deposition. The temperature of a heating zone was maintained at 750° C. for 4 hours while 10 sccm of hydrogen gas was supplied in order to remove an oxide layer from the surface of the titanium buffer layer formed on the target substrate. At this time, the target substrate was maintained at a temperature of 150° C., and the internal pressure of the chamber was maintained at 0.6 Pa. It is known that titanium oxide is easily reduced by treatment with hydrogen plasma or in a hydrogen atmosphere.
(30) Next, the temperature of the heating zone was elevated to 1100° C. so that CH.sub.4 could be decomposed. Also, CH.sub.4:H.sub.2 (1:10-40 or (1-10)/10 sccm) was supplied as a reactive gas, and graphene was grown under a condition in which the temperature of the target substrate was 150° C. The working pressure was controlled in the range of 0.6 to 6.6 Pa.
(31) In order to confirm that graphene was grown in the target substrate by the above-described method, Raman spectra were measured (UniRAM-5500, 532 nm laser), observation with AFM was performed, and EELS (electron energy-loss spectroscopy) mapping was performed. For ADF TEM, a 200 nm-thick SiO.sub.2 layer was deposited on the graphene layer by plasma damage-free facing-target sputtering.
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(33) Among the above-described conditions, the following conditions made it possible to grow the best quality graphene at 150° C.: 4 hours of annealing in a hydrogen atmosphere; working pressure of 0.6 Pa; and CH.sub.4:H.sub.2=1:10. The I.sub.2D/I.sub.G, I.sub.D/I.sub.G and FWHMs of 2D-band and G-band of the grown graphene thin film were 2.10±0.08, 0.02±0.01, 37±1 cm.sup.−1 and 21±2 cm.sup.−1, respectively.
(34) However, despite 4 hours of annealing in a hydrogen atmosphere, it was difficult to realize grown graphene having an area larger than micrometers, due to residue of titanium oxide. Even when the time of annealing in a hydrogen atmosphere was increased to 5 hours, there was no change in the graphene growth area.
Example 2: Growth of High-Quality Graphene on Titanium Buffer Layer
(35) It was believed that when the process of forming a titanium buffer layer and graphene was performed in a state in which an oxygen-free atmosphere was maintained, graphene could be produced with high quality. Accordingly, a system shown in
(36) Using the system shown in
(37) Specifically, on each of the above-described SiO.sub.2/Si, glass and PET target substrates, a 10-nm-thick titanium buffer layer was formed by DC sputtering at 150° C. under the following conditions: DC power of 20 W; base pressure of 6.6×10.sup.−4 Pa; working pressure of 0.4 Pa; and deposition time of 2.5 minutes. Immediately after deposition of the titanium buffer layer, a graphene thin film was grown by plasma-enhanced thermal CVD at 150° C. under the following conditions: rf power of 70 W; base pressure of 6.6×10.sup.−4 Pa; working pressure of 2.4×10.sup.2 Pa; growth time of 1.5 hours; Ar/H.sub.2/CH.sub.4 flow rates of 12/10/0.5 sscm; distance between rf anode and cathode of 8 cm; and distance between rf source and target substrate of 10 cm.
(38) For ADF TEM to confirm graphene growth, a 200-nm-thick SiO.sub.2 layer was deposited on the graphene layer via plasma damage-free facing-target sputtering. The Ti/glass target substrate in the graphene/Ti/glass target substrate was dissolved using hydrofluoric acid, and then the separated graphene monolayer was transferred onto a copper grid, and the crystallinity of the graphene was analyzed by TEM (HRTEM) and SAED (selected-area-electron-diffraction).
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Example 3: Evaluation 1 of Characteristics of Graphene
(40) To analyze the energy characteristic of Ti in the graphene/Ti/substrate obtained in Example 1, the graphene/Ti/PET was measured by XPS (
(41) It was shown that Ti in the Ti/PET maintained in an oxygen-free state had a binding energy of Ti 2p.sub.1/2=460 ev, Ti 2p.sub.3/2=453 ev, whereas the binding energy of Ti in the graphene/Ti/PET, taken out of the system after production and exposed to air, was Ti 2p.sub.1/2=464.4 ev, Ti 2p.sub.3/2=458.4 ev, indicating that the Ti had a TiO.sub.2 phase. This suggests that the produced graphene/Ti/substrate was oxidized quickly to a graphene/TiO.sub.2/substrate by exposure to an external environment.
(42) Meanwhile, the electrical conductivity of Ti is 2.3×10.sup.4/Ωcm, whereas the electrical conductivity of TiO.sub.2 is extremely as low as 1.65×10.sup.−10/Ωcm. Therefore, in an actual use environment (atmospheric exposure), Ti is immediately oxidized to TiO.sub.2 which is an insulator, and thus the Ti film does not substantially exhibit electrical characteristics. This demonstrates that TiO.sub.2 in the graphene/TiO.sub.2/substrate produced by the method of the present invention substantially acts as an insulator, and thus the graphene/TiO.sub.2/substrate may be applied directly to a device or a transparent conductive layer without removing the TiO.sub.2 layer, that is, without a transfer process.
Example 4: Evaluation 2 of Characteristics of Graphene
(43) The various characteristics of the graphene layer in each of the graphene/Ti/SiO.sub.2/Si, graphene/Ti/glass and graphene/Ti/PET obtained in Example 2 were evaluated, and the results are shown in
(44) “a” of
(45) “b” of
(46) “a” and “b” of
(47) As can be seen in of
(48) The graphene thin film grown to a large area (4×4 cm.sup.2) was divided into 25 portions according to the beam size (0.8 cm) of the UV-vis spectrometer used, and then the transmittance of each portion was measured. The results are shown in “d” of
(49) “c” and “d” of
(50) The sheet resistance (“e” of
(51) “f” of
Example 5: Application to Flexible and Transparent Thin Film Capacitor
(52) In recent years, attempts have been made to imbed passive components (80% of electronic components) such as capacitors into printed circuit boards (PCBs). In addition, electronic devices are designed to be flexible, and thus flexibility becomes a major requirement for electrodes and materials a high dielectric constant. Up to now, the bottom electrodes in embedded and flexible thin-film capacitors have been fabricated by transferring graphene, growth on Ni catalyst layers, onto flexible target substrates.
(53) In this Example, the graphene thin film of graphene/Ti/PET produced in Example 2 was used as a bottom electrode, and a graphene thin film grown on titanium at 150° C. was used as a top electrode, thereby fabricating a flexible and transparent thin-film capacitor, and the characteristics of the capacitor were evaluated. It was reported that 200 nm-thick BMNO (Bi.sub.2Mg.sub.2/3Nb.sub.4/3O.sub.7) pyrochore thin films deposited onto copper-clad laminate and Pt/TiO.sub.2/Si substrates at room temperature showed a high dielectric constant of 40-60 at 100 kHz and a low leakage current density of 10.sup.−8 A/cm.sup.2 t room temperature. Thus, BMNO was chosen as a dielectric material. On the graphene/Ti/PET substrate having a size of 4×4 cm.sup.2, produced by the method of Example 2, a 200 nm-thick BMNO dielectric thin film was formed by plasma damage-free FTS (facing-target sputtering) under the following conditions: rf power of 100 W; working pressure of 0.65 Pa; and Ar/O.sub.2 flow rates of 10/10 sccm. For formation of a top electrode, a disk-shaped titanium buffer layer having a diameter of 150 μm and a thickness of 10 nm was deposited on the BMNO thin film according to the same method as the method of Example 1, and 10 nm-thick graphene was grown thereon at 150° C. Raman mapping indicated that the graphenes grown as the top electrode and the bottom electrode were formed as monolayer graphene (
(54) As shown in
(55) The dielectric properties of the BMNO thin films were measured as a function of frequency using an impedance/gain-phase analyzer (HP4194A), and the results are shown in
(56) For comparison, a thin-film capacitor was fabricated using a top electrode having only a Ti layer (substantially, only a TiO.sub.2 layer) having no graphene layer formed thereon, and the dielectric characteristics and leakage current characteristics thereof were measured. As a result, the capacitor for comparison showed very unstable dielectric characteristics and a high leakage current value (
(57) To examine the flexibility of the graphene/Ti/BMNO/graphene/Ti/PET capacitor, a bending test was performed to evaluate the dielectric and leakage current characteristics of the BMNO thin-film capacitor (
(58) As described above, the method for producing a graphene thin film according to the present invention makes it possible to grow a defect-free, monocrystalline graphene thin film over a large area on a target substrate without changing the transparency and electrical properties of the target substrate, and thus can produce good-quality graphene by a transfer-free method.
(59) Furthermore, according to the method of the present invention, graphene with excellent crystallinity can be grown even when the temperature of the target substrate is as low as 400° C. or below, particularly 150° C. Accordingly, a graphene layer can be grown directly using a flexible target substrate made of a polymer material such as PET, thus providing a flexible device or a transparent electrode.
(60) A monolayer graphene thin film produced by the method of the present invention has excellent electrical properties such as mobility and resistance, and thus can substitute for metals such as copper, which are used in flexible electronic devices.