Wonsuk
Jung‡
a,
Taeshik
Yoon‡
a,
Jongho
Choi
b,
Soohyun
Kim
a,
Yong Hyup
Kim
*b,
Taek-Soo
Kim
*a and
Chang-Soo
Han
*c
aDepartment of Mechanical Engineering, KAIST, Daejeon, 305-701, Republic of Korea. E-mail: tskim1@kaist.ac.kr
bSchool of Mechanical and Aerospace Engineering, Seoul National University, Gwanak, Seoul 151-744, Republic of Korea. E-mail: yongkim@snu.ac.kr
cSchool of Mechanical Engineering, Korea University, Anam, Seongbuk, Seoul 136-701, Republic of Korea. E-mail: cshan@korea.ac.kr
First published on 17th October 2013
We report a superstrong adhesive of monolayer graphene by modified anodic bonding. In this bonding, graphene plays the role of a superstrong and ultra-thin adhesive between SiO2 and glass substrates. As a result, monolayer graphene presented a strong adhesion energy of 1.4 J m−2 about 310% that of van der Waals bonding (0.45 J m−2) to SiO2 and glass substrates. This flexible solid state graphene adhesive can tremendously decrease the adhesive thickness from about several tens of μm to 0.34 nm for epoxy or glue at the desired bonding area. As plausible causes of this superstrong adhesion, we suggest conformal contact with the rough surface of substrates and generation of C–O chemical bonding between graphene and the substrate due to the bonding process, and characterized these properties using optical microscopy, atomic force microscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy.
However, natural contact between graphene and the substrate hardly ensures control over the adhesion energy and durability in several applications. Strong adhesion of graphene is required to avoid problems with delamination, reliability, vapor permeation, and other factors.7,9–11 Graphene can be easily detached from substrates by wet chemical processes to produce graphene FETs or nanoribbons.9 In addition, delamination of graphene from the substrate degenerates the charging and discharging ability of graphene fuel cells.10,11 Moreover, weakly bonded graphene can also be wrinkled and folded over long exposures to high humidity.7 In order to reinforce and control the graphene adhesion, conventional bonding methods can be considered but have not been tried yet.6,12–14 For example, bonding through an adhesive interlayer, such as glue or epoxy, may be the simplest process to adhere graphene to the target substrate.15 However, this method produces a thick adhesive layer in the range of tens of micrometers that is nonuniform in height, which can be subject to parasitic effects from the substrate, and inefficiently transfers heat with a coefficient of approximately 2–5 W m−1 K−1. The second approach is a non-epoxy bonding method, such as high temperature bonding,14 plasma bonding,12 and eutectic or thermo-composition bonding using a metal interlayer.13 However, these methods require high temperatures of up to 1000 °C, O2 plasma treatment, and the addition of metal materials to an interlayer at high pressures, which could seriously damage graphene. Therefore, enhancing the bonding force of graphene to substrates is of significance to many applications. Moreover, the use of graphene as an adhesive between two substrates has not yet been exploited.
In this paper, we explore a new role of monolayer graphene in anodic bonding as an adhesive between SiO2 and glass substrates. Anodic bonding has been widely used in the Si industry16 and in a broad range of other fields.17 This bonding method has been used for bonding glass substrates to target materials,18 such as Si, metals (Alloy 42, Invar, Kovar, Ni),19 and oxide materials (SiO2). The principle of anodic bonding is based on the conductive solid electrolyte state of glass over 250 °C that has an alkali composition containing Na2O or K2O (for example, Pyrex 7740 from Corning or Boro 33 from i-Nexus) and high electrostatic forces that result in an ion depletion layer at the bonding interface under applied voltage, typically on the order of several kilovolts across the bonding substrates.20 The cathode and anode are conventionally connected to the surfaces of glass and Si substrates to generate high potential voltage, inducing migration of Na+ and K+ ions that were already decomposed from Na2O and K2O at the high temperature. The decomposed alkali ions, such as Na+ and K+, have higher mobility than O2− ions; therefore, they migrate to the cathode plate connected to the glass substrate. The remaining O2− ions generate high electrostatic forces at the interface between the glass and counter substrate.18 The counter substrate, typically a Si wafer, does not decompose into ions; instead, it retains its original composition, except at the bonding interface. The strong electric field at the interface pulls the wafer into intimate contact with the substrate, ultimately leading to the formation of stable Si–O–Si bonds and resulting in a strong bonding of the wafer to the glass substrate.18 Recently, electrostatic forces induced by high voltages were used to exfoliate graphene from highly oriented pyrolytic graphite (HOPG).18,21–23 Instead of using a Si substrate in the anodic bonding process, HOPG was used as a positive electrode and a glass substrate was used as a negative electrode.18,21,22 Additionally, a SiO2 substrate was adopted as a negative electrode to transfer graphene from graphite to SiO2 by anodic bonding.23 However, this method is imperfect because it can only exfoliate local areas of graphene.
Bonding uniformity was investigated by void observation, as presented in Fig. 1b and c. In the case of strong bonding, there was a transparent graphene area on the SiO2 because of the absence of voids (Fig. 1b). The graphene area is darker in color because monolayer graphene has a maximum transparency of approximately 97.7% under white light.24 On the other hand, if the sample is not bonded in the control experiment or has low bonding energy, Newton's rings are formed due to the effect of light interference, as shown in Fig. 1c and S4.† Moreover, these unbonded samples are easily detached from each other. The conformal close contact between graphene and the substrate can be observed in cross-sectional images of the SiO2/Si, graphene, and glass layers (Fig. 1d). Even though there are some ripples of transferred graphene, the space charging of the depletion layer, which generates strong interfacial electrostatic attractive forces, induces conformal contact of graphene to the substrate.
The crack length was calculated from the slopes of the curves. The adhesion energy was calculated from the corresponding crack length and critical load of each cycle. We observed that the cracks were more likely to propagate in the glass beam than at the interface when the speed was high. To prevent propagation in the glass beam, the test speed was fixed at 0.5 μm s−1. Some of the crack lengths are depicted in Fig. 2b. The measured adhesion energy for each condition is plotted in Fig. 2c. From these results, the highest and lowest adhesion energies were obtained for C1 and C4, respectively. The dominant factor for adhesion was temperature. The adhesion energy was 0.4 J m−2 at 280 °C, whereas it increased by approximately three-fold at 380 °C. Graphene adhesion is tunable and its adhesion could be increased to a maximum of 1.4 J m−2 and an average value of approximately 1.05 J m−2 at 380 °C by modifying the anodic bonding. The adhesion energy of graphene was higher under the conditions in this study than for the original anodic bonding conditions used for Si and glass wafers, which displayed lower adhesion energies of 0.4–1.25 J m−2 at 300–400 °C and 500–2000 V (ref. 25) to 70 mJ m−2 at 250 V and 240 °C after oxygen plasma pretreatment.26
Additionally, to prove that the graphene produced higher adhesion energy, we suspended a heavy fire extinguisher in both the normal and shear directions (Fig. 2d). The tab for the wire used to hang the object was attached to the bonded sample by epoxy (see the ESI†) after the process shown in Fig. 1a. This specimen had a small area of 0.8 cm2 (4.5 mm width and 18 mm length), which was fixed on the aluminum plate (Fig. 2d). A heavy fire extinguisher (39 cm high, weighing 5.2 kg) was then hung from the tab. The calculated stress exerted on the graphene was 0.65 MPa. There was no change in the bonded interface after several accelerated motions (the maximum of 12.1 m s−2 with a 0.00479 m s−2 sensor resolution) in various directions. Although a heavier object (22 kg) was also used to test the strength of the graphene adhesion, a crack occurred in the upper part of the glass substrate rather than at the interface between the graphene and glass or SiO2 substrates (Fig. S3†). This result indicated that the graphene adhesion was extremely strong between the SiO2 and glass.
To account for the strong adhesion strength, not only van der Waals force but also Coulomb interactions should be considered. The sodium transport makes space charge at the interface and this pulls both beams. We calculated the electrostatic pressure based on a parallel plate capacitor model, obtaining a value of 0.17 MPa.39,40 This is 26% of the previously measured adhesion strength. However, the actual contribution would be less than this because the amount of space charge would be reduced with removal of the electrical field. Therefore, we assumed that the major contribution for strong bonding was chemical bonding, and this is discussed in the next section.
First, surface characterization of the fracture interface was carried out by optical microscopy and AFM after anodic bonding (Fig. 3). The optical images of the SiO2 fracture surface displayed large amounts of glass residue after detaching the glass substrate from the SiO2 in the DCB test. As the sample had stronger adhesion, a considerable amount of glass residue remained on the surface (Fig. 3a), which indicated that there was stronger chemical bonding between graphene and SiO2 or glass than chemical bonding between the glass atoms because a crack grew in the interior of the glass. For the lowest adhesion energy, scattered small dark areas appeared but glass residue was not observed (Fig. 3b). Other cases are presented in Fig. S2.† The optical 3D profile displayed a large glass residue deposit of approximately 32 μm in height (Fig. 3c). The dark area distributed around the glass residue was graphene (Fig. 3a). To identify the existence of graphene in the dark areas, we investigated the image and height profiles by AFM (XE-100, PSIA Company) (Fig. 3d). Based on the height profiles along the green and red lines in the topographic image of the black area (Fig. 3d), the height of the dark area was only approximately 2.6 nm, with uniform roughness along the dark area. The distance between the exfoliated monolayer graphene and the SiO2 was approximately 1 nm, which was ascribed to the weak interaction of graphene with SiO2.30 In our experiments, the increased height of the graphene area was attributed to a change in the graphene structure due to C–O covalent bonding. In general, graphene oxide has a greater thickness of 1–2 nm than monolayer graphene (0.34 nm) because of oxidation.31 Some graphene/glass areas detached from the SiO2 when there was strong bonding between the graphene and glass atoms. This phenomenon can be observed as bright areas on the SiO2 substrate.
We also observed Raman spectra to confirm the existence of graphene in the dark areas and analyze the properties of graphene. Raman spectroscopy is a powerful method for characterizing graphene samples30 in terms of doping,32 defects, and the number of layers.22 The Raman spectra were acquired using a high-resolution dispersive Raman microscope (ARAMIS, Horiba Jobin Yvon) under an excitation wavelength of 514.5 nm. According to the black line in Fig. 4a and b, the intensity of the 2D peak at 2702 cm−1 is approximately twice the intensity of the G peak at 1591 cm−1 before anodic bonding. This result indicates that graphene existed as a monolayer on the SiO2/Si substrate.33 An upshift of the G peak from 1580–1588 cm−1 indicated p-doping of graphene on the SiO2/Si substrates, which resulted from the trapped charges in the oxide or at the graphene–oxide interface.34
The Raman spectra of the graphene on the fracture interface indicated an increase in the D peak and a decrease in the 2D and G peak with increasing adhesion energy. The ratio of intensity (ID/IG) depends on the magnitude of the bonding energy. The intensity ratios were 0.66 (C4), 1.11 (C3), 1.75 (C2), and 1.98 (C1) on SiO2 and 0.81 (C1), 0.95 (C2), 1.71 (C3), and 1.85 (C4) on glass (insets of Fig. 4a and b). Because the D peak is caused by graphene defects, the increase in the intensity of the D peak was likely due to strong bonding from C–O covalent bonds. Additionally, the D peak can be increased by deformation of graphene, which can attach to the rough surface of the substrate and produce higher conformity under high voltage. The deformation of graphene can cause more disorder in the sp2 structure.23 After the DCB test, the strong bonding between the graphene and glass caused some graphene areas to move toward the glass substrate. The intensity ratio of the Raman spectra of the glass also indicated that covalent bonding occurred at the interfaces between the graphene and the glass and SiO2.
Other interesting features of the Raman spectra included the presence of D′ peaks at 1628 cm−1 that were separate from the G peaks and blue shifts of G peaks from 1591 cm−1 before bonding to approximately 1602 cm−1 after bonding, as shown in Fig. 4a and b. The intensity of the D′ peak gradually increased with increasing bonding energy on both sides of the SiO2 and glass substrates (Fig. 4a and b). The G and D′ peaks at approximately 1628 cm−1 were analyzed by separating each peak by a Lorentzian line. Fig. 4c presents the Lorentzian fitted curves of the Raman spectra from 1500 to 1700 cm−1. The new peak at 1628 cm−1 increased dramatically with increasing adhesion energy. We also described the effect of temperature and voltage based on the ratio of the area of the decomposed G and D′ peaks, as shown in Fig. 4d. The highest ratio was 0.394 (C1), and the lowest ratio was 0.078 (C4). The other cases exhibited ratios of 0.214 (C3) and 0.381 (C2).
Similar phenomena for the blue shift of the G peak and the appearance of the D′ peak have been reported for the Raman spectra of graphene oxide.35,36 The D′ peaks from graphene oxide can be explained by the activation of phonons due to phonon confinement by the defects.35 The blue shifting of the G peak can be attributed to the presence of isolated double bonds that resonate at a higher frequency in GO.37 From these results, the presence of a D′ peak at 1628 cm−1 and a blue shift of the G peak can be attributed to C–O bonding, indicative of the formation of graphene oxide between graphene and the SiO2 or glass substrates. In other words, some of the graphene bonds changed from CC to C–C and C–O.
As shown in Fig. 5a, water contact angles of the anodic bonded graphene on glass substrates were measured to observe the surface change after bonding. The contact angle decreased after bonding, which reveals that the surface energy increased after the anodic bonding. In order to characterize the components of atoms and the type of bonding at the interface between graphene and glass or SiO2 substrates, XPS can be used.38 We used multi-purpose XPS (MultiLab2000, Thermo VG Scientific Co.). After the DCB tests, the glass surfaces, where the graphene remains, were analysed to observe the exact chemical bonding of graphene on glass. The obtained XPS spectra, ranging from 293 to 279 eV, are shown in Fig. 5b. The spectra show two representative peaks, at 284.5 and 286.1 eV, corresponding to the C–C and C–O bonds of graphene, respectively. It is shown that the C1 and C2 conditions have higher intensity at 286.1 eV than the other conditions. We estimated the number of C–O bonds on the glass surface. The surface atom density of graphene is 3.82 × 1015 cm−2 (ref. 42) and the maximum ratio of C–O/C–C peak is 0.34 under the C1 condition, and thus the number of C–O bonds is 1.29 × 1015 cm−2. These results indicate that the high adhesion energy under the C1 and C2 conditions is due to the formation of C–O bonds between graphene and glass. Moreover, temperature is the dominant factor for ensuring strong anodic bonding of graphene.
Footnotes |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c3nr03822j |
‡ These authors contributed equally to this work. |
This journal is © The Royal Society of Chemistry 2014 |