Graphene Printed Electronics for Energy: Supercapacitors, Heating Films and Integrated Sensors

Graphene enables the printing of conductors, sensors and heating surfaces directly onto polymer films. Coupled with supercapacitors, this thin electronics delivers power peaks, precisely measures system status and manages temperature with minimal footprint. Target applications: micro-mobility, industrial IoT, embedded equipment.

Why Associate Electronics and Energy with Graphene

Conductivity + flexibility: tracks, antennas, measurement shunts and heating resistances on thin films (PET/PI).

Immediate power: supercapacitors absorb and restore accelerations, motor starts or radio pulses.

Integrated sensors: temperature, stress, humidity/gas to control safety and efficiency.

Volume-compatible processes: screen printing and roll-to-roll, therefore controlled costs and repeatability.

Graphene Supercapacitors: The Power "Buffer"

Graphene-based supercapacitors serve as rapid power reservoirs.

Use cases:

• Micro-mobility: regenerative braking recovery and more responsive acceleration while preserving the battery.
• IoT/industry: powering actuators and long-range transmissions between two standby phases.

To monitor: low ESR, controlled leakage current, cold weather behavior and battery-supercap coupling strategy via BMS/EMS.

Graphene Heating Films: Defrost, Maintain, Stabilize

A resistive network printed with Graphene diffuses homogeneous heat over large surfaces, with rapid temperature rise.

Typical uses:

• Defrosting/defogging of optics, sensors and glazing.
• Temperature maintenance of mechatronic assemblies to guarantee cold-weather performance.
• Comfort: wall panels and towel warmers with low thickness.

Discrete industrial player example: Swiss company GRAPHENATON Technologies SA manufactures Graphene heating films through printed electronics (inks deposited on polymer film, lamination and encapsulation).

Best practices: PWM control, track geometry to smooth heating, co-printed temperature sensors for closed loops, appropriate vapor barrier (encapsulation).

Printed Sensors and Tracks: Integrated Measurement and Traceability

• Current measurement shunts for state estimation and anomaly detection.
• Temperature/stress/humidity sensors placed closest to critical areas.
• Printed NFC/RFID antennas for traceability, maintenance or wireless configuration.

Benefit: low-cost meshed telemetry and extended pack lifespan.

Typical Architecture of a "Graphene × Energy" Module

1. Polymer substrate (PET/PI).
2. Graphene tracks (power + measurement).
3. Heating zone (resistive pattern).
4. Dielectric/passivation layers.
5. Connection islands (busbars, press-fit/conductive rivets).
6. Supercapacitors + BMS/EMS.
7. Lamination & encapsulation (moisture/oxygen barrier).

Qualifications to plan: sheet resistance, adhesion, thermo-hygro cycling, heating tests (uniformity, ramp-up), electrical endurance.

Three Integration Scenarios

1) Micro-mobility

Supercaps for regeneration and restarts.
Printed temperature sensors/shunts to control current and safety.
Expected effect: stable power, less stressed battery, more useful cycles.

2) Autonomous IoT in Harsh Conditions

Antenna + printed sensors + mini heating patch.
Supercap for radio pulse (LoRa/Cellular).
Expected effect: reliable cold-weather transmissions, reduced maintenance.

3) Optics and Sensor Defrosting

Ultra-thin heating film behind the surface, controlled by co-printed temperature sensor.
Expected effect: rapid defogging, controlled consumption, virtually invisible integration.

Quick Checklist (Product Team)

• Priority objective: power (supercaps), autonomy (battery) or hybrid?
• Usage profile: temperature, humidity, vibrations, chemical agents.
• Active surfaces: necessary heating zones? embedded sensors?
• Standards: EMC, electrical safety, flammability, RoHS/REACH.
• Purchasing: datasheet consistency (flake size, C/O ratio, viscosity), batch-to-batch repeatability.
• IP: patent review on heating patterns, inks, connectors and processes.

Frequently Asked Questions

Does Graphene replace copper?

No. It opens the way to very thin and conformable printed conductors and sensors, where copper is too thick or expensive to integrate.

Why add supercapacitors if I already have a battery?

They handle power peaks (accelerations, RF pulses) and reduce battery stress, which improves lifespan.

Do heating films consume a lot?

Power is controllable (PWM, zoning). Rapid temperature rise limits activation time and therefore energy consumed.

What durability in humid environments?

With appropriate encapsulation, performance remains stable. Thermo-hygro cycles validate the design before production.