
- Journal of Semiconductors
- Vol. 43, Issue 6, 061101 (2022)
Abstract
1. Introduction
Graphene is an exceptional carbon crystal composed of single-layered materials made up of six bonded sp2 carbon atoms, configured in a honeycomb lattice nanostructure with an atomic spacing of 1.42°. It is the underlying element present in graphitic materials: fullerene (0D), nanotubes (1D), graphite (3D). Andre Geim, and Kostya Novoselov discovered this material in 2004 at Manchester through a method called “Scotch tape peeling” by using adhesive tape to separate an isolated monolayer graphene from graphite. Hence, the graphene layers produced are greatly ordered; possess unique and excellent electrical, mechanical, optical and thermal properties and this has meant that it has drawn lots of attention to itself[
Since its discovery, the major challenge to the productive future application of graphene as an alternative to silicon in new generation electronics commercially is the absence of an energy band gap due to its symmetry, which unites two types of distinct carbon atoms. Therefore, there is a need to open a finite gap of graphene in the energy dispersions at K-point through several techniques. These techniques should be cost effective in manufacturing or fabricating high quality and large area graphene sheets[
Furthermore, in recent reports (CVD) and epitaxial methods are adopted in the synthesis of graphene to open the band gap and are promising in the generation of monolayer area quality graphene on a large scale. These methods are not without its challenges, because the reduction of graphene oxide chemically includes the use of hydrazine, dimethyl hydrazine and its derivatives that are highly poisonous and harmful to humans and the environment. In addition, other negatives of CVD are that these chemicals have adverse effect on biomaterials, electrochemical storage device and polymers and these contributes to increase in the cost of production of graphene on an industrial scale[
Hence, most recently the biological reduction of graphene through plants extracts and microorganisms are developed as alternative to the use of hydrazine as a natural reducing agent in the reduction of graphene oxide to manufacture graphene on a large scale[
Besides, the preparation of graphene at the macroscale by liquid phase exfoliation to form a graphene oxide (GO) halfway, which is followed by reduction to maintain the graphene structure (RGO). Nevertheless, it was determined that the composition of poor dispersion, sheet defects restacking and multilayer thickness could limit the complete realization of the high surface area and electronic properties of graphene[
2. Production of graphene
Synthesis of graphene is the process of contingent on the preferred purity, size and crystallinity of the individual by-product. Interestingly, the synthesis of graphite was reported in 1975 when Lang showed the formation of single- and multi-layered graphite by thermal decomposition of carbon crystal on platinum substrates but was not classified as graphene owing to lack of techniques on characterization[
The challenge was the inability to identify the applications of the by-product and the properties of the layers produced on the crystal planes of platinum were not uniform, this prevented a thorough study on the material in the early days. However, after a long while, in 1997 respectively, it was reported that graphene was grown on a crystal substrates of a transition metals and metal carbides by decomposing hydrocarbon gases at elevated temperature. In addition, in 1999 the physical properties of the edges of graphene were studied by growing epitaxial nano-sized films with a ribbon structure on a Ni substrate by Oshima et al.[
Furthermore, the study on graphene synthesis has grown since the early studies of graphene on Pt substrates; this is because it is believed that it can herald the development of next generation electronics and technologies owing to its extraordinary properties[
Figure 1.(Color online) Structures of (a) 3D graphite, (b, c) 2D graphene and its edge, (d, e) graphene oxide, (f) reduced graphene oxide[
However, to circumvent the production of undesirable and toxic by-product with the adoption of sustainable, dependable and environmental approach. The green synthesis of graphene is backed to aid several biological materials like phytoextracts, algae, fungi and bacteria[
2.1. Top-down approach
This is the process of breaking down or reducing graphite into nano sized graphene sheets, which are easily complexed with separate functional materials to produce novel materials[
Figure 2.(Color online) Top-down and bottom-up approaches for synthesis of graphene[
2.2. Mechanical exfoliation
This is the first and one of the most widely utilized method employed to synthesize graphene from graphite, which uses mechanical forces to separate the layers from each other to obtain graphene. However, within the graphite sheets are Van der Waals bonds, which can be broken down when exfoliating graphene using normal or lateral forces[
2.3. Ball milling
Ball milling is an emerging method to fabricate high-quality graphene by breaking down stacked graphite into graphene. Interestingly the ball-milling process was reported to have started about 150 years ago where it was employed in the talc powders, size communications of ore and several other applications. However, in the last two decades, the technique is proposed for the creation of nano-sized particles at room temperature[
Figure 3.Schematic diagram of the soluble salt assisted (Na2SO4) wet ball milling approach for synthesis of graphene nanosheet powder[
Figure 4.(Color online) (a) Pure graphene. (b) Dry ice. (c) Edge-carboxylated graphite prepared by ball milling for 48 h. (d) Schematic view of physical cracking and edge-carboxylation of graphite by ball milling in the presence of dry ice, and protonation[
Figure 5.(Color online) Schematic view: preparation of graphene oxide in laboratory designed ball mill[
In addition, Casallas Caicedo et al. reported the oxidation of graphite by the ball-milling method with the aid of potassium perchlorate and purified water to exfoliate graphene from graphite (Figs. 3–5). It was discovered that the degree of oxidation increased as the milling time increases. In addition, the effects of the oxidation were examined based on the grinding time intervals (6, 12, 18, 24, 30 h) in this approach and the obtained samples in the ball milling are compared with the outcome of the Hummers methods. Hence, the sample showed better dispersion and a darker color after 18 h of milling which is due to removal of functional groups like carboxyl, hydroxyl and epoxy[
2.4. Sonication
Sonication-assisted liquid-phase exfoliation is an efficient method, which can synthesize mass production of high-quality single- or few-layer graphene[
Figure 6.(Color online) Schematic view of tip sonication processing with parameters that influence graphene nanoplatelets dispersion in a liquid medium with obtained phenomena. (a) Fragmentation. (b) Exfoliation. (c) Defect[
Krishnamoorthy and his group also reported a simple sonochemical method of the reduction of graphene oxide into graphene nanosheets in a small reaction time. However, graphene oxide was reduced to graphene nanosheets, which resulted in the agglomeration of graphene oxide, which inhibits the efficiency of reduction; thereby the removal of oxygenated functional group was not entirely realized. Hence, ultrasonication is used to exfoliate graphitic oxide into graphene oxide, as indicated in Figs. 7 and 8[
Figure 7.(Color online) Separation of graphitic oxide by sonication for 0.5 h.
Figure 8.(Color online) Sonochemical synthesis of graphene oxide into graphene nanosheets in the presence NaOH[
2.5. Electrochemical exfoliation
Electrochemical method is increasingly gaining attention in the production of graphene. It is different from wet chemical exfoliation method, as it does not require the use of harmful oxidants[
Figure 9.(Color online) Image of graphite flakes after electrochemical exfoliation. (b) Dispersed EG in DMF solution (concentration 2.5 mg/mL). (c) EG size on a bulk scale (163 g). (d) Diagrammatic representation of the principle of electrochemical exfoliation[
2.6. Bottom-up approach
This approach is a layer-by-layer method that begins with the formation of small molecular carbon atoms to derive graphene. However, epitaxial growth of graphite on SiC, chemical vapor deposition, chemical reduction are the prominent method used[
2.7. Epitaxial growth on SiC
In this approach monolayer and few layers graphene sheet can be grown by the depletion of the surface of Si on SiC substrates at a high temperature in a vacuum[
Figure 10.(Color online) (a) Schematic view of the configuration used for face-to-face growth technique setup; (b) magnified view of the sample set up highlighted in panel (c) enlarged view of mounted SiC substrates highlighted by red lines in panel[
2.8. Chemical vapor deposition (CVD)
The CVD method is a bottom-up approach and is one of the main techniques utilized for preparing large-area high quality graphene. Graphene is created on surfaces of various transitions metals surfaces for example, Ni and Cu foils used as substrates from different vapor classes as a carbon source through chemical reactions. Optimizing the parametric growth process like energy, pressure, flow of carrier gas has been utilized to regulate the growth process[
Figure 11.(Color online) (a) Roll-to-roll process for the transfer of FLG from Ni foil to EVA/PET metal surface[
In 2011, Hesjedal investigated the continuous growth of few-layer, and potentially single-layer, graphene on Cu foils, which run through an atmospheric CVD system in a roll-to-roll process[
Zhao et al.[
In the same vein, Dong et al.[
Al-Hilfi et al.[
Lee and his group[
Figure 12.(Color online) The graph of the sheet resistance versus the transmittance of the FLG/EVA/PET samples[
Vlassiouk et al. examined that large-scale high-quality synthesis can be executed utilizing atmospheric pressure chemical vapor deposition on Cu foil Fig.13. The results show that an atmospheric approach can annihilate the difficulties related with low-pressure CVD process while enabling the development of this innovation to the roll-roll industrial scale graphene generation[
Figure 13.(a) Pure VCCD-MWNT revealed the graphene helices released from the walls. (b) Milled for 1 h. (c, c’) Milled for 120 min[
Despite the significant progress with the CVD method to grow graphene on the transition metal surface to produce graphene with high quality, fine grained and better hardness over other coating methods, a portion of the under recorded difficulties endures. The gaseous by-product of the process is for the most part destructive. This is on the grounds that the precursor gases used are highly volatile for it to react with the metal surface, yet it should not be too volatile to transport them to the reaction chamber[
2.9. Non-toxic reducing agents
The chemical method in the reduction of graphite oxide (GO) is one of the most important, and generally accepted process to obtain quality and uniform graphene film. Despite this success, the evidence of trace amount of toxic reducing agents in the produced graphene film are harmful to humans and are not environmentally friendly[
However, the significant qualities of these plant extracts are their superabundance in nature, cost effectiveness with their distinct physicochemical attributes. More so, the plant extracts contain a few carbolic compounds like chlorogenic acids, gallic acids, salicylic acids and vanillic acids etc. The phytoextracts will assist with turning away the accumulation in an aqueous dispersion of the arising RGO through electrostatic repulsion exchange of the negative charge densities of the diverse carboxylic group[
Lee & Kim studied seven plant extracts, which include cherry, platanus, persimmon, magnolia, maple, pine, and ginkgo and compared their potentials to reduce graphene oxide [
In 2011, Kartick et al.[
Figure 14.(Color online) Image of powder and the aqueous dispersion of graphene oxide (0.5 mg/mL) before (left) and after reduction (right)[
Figure 15.SEM image of graphite-oxide[
The deoxygenation of GO by means of C. Colocynthis leaf extract polyphenols as a reducing agent was presented by Zhu et al.[
Figure 16.TEM images of graphite oxide[
Besides, De Silva et al.[
Figure 17.Plot of thermogravimetric analysis of (a) graphite oxide and (b) graphene[
Figure 18.(Color online) Schematic view of the oxygen functionalities in GO and RGO[
3. Conclusions and perspective
The carbon material ‘graphene’ has gained significance in the field of micromanufacturing, nanomaterials, biomedical, and composite materials owing to its high surface area thermal, electronic and physical properties. Be that as it may, the mass production of graphene for its wide range of applications rely on the production techniques and attracted with significant attention recently. Therefore, optimizing the production method is vital for expanding the yield, producing high quality graphene and most importantly adopting facile, cost-effective and environmentally benign method is the way forward. Hence, future study should be fixed on working with the measure of yield, biocompatibility as the use of poisonous chemicals, high energy, pressure and poor transfer process in chemical approaches that have contributed significantly to high-cost of production, poor yield and imperfections in the obtained graphene. All things being equal, the headway of novel methods and green sources is essential for synthesis of graphene materials in electronics, nanomaterials and biomaterials. The production creation methods and carbon sources are important in determining the size, morphology and optical characteristics of the obtained material. In a nutshell, despite myriads of research on the production of graphene since its discovery, none of the approaches fully satisfy its production on an industrial scale. This overview provided a comparative study as well as possible applications of graphene and discussed the potential methods.
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