Inventing the future: philly startup is at the forefront of

a consumer electronics revolution

DANA HENRY | TUESDAY, FEBRUARY 05, 2013

THE GRAPHENE TEAM

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Imagine a material that's invisible to the naked eye, ten times stronger than diamond,
incredibly flexible, impermeable to gases and the world's best-known conductor of
electricity. It's called graphene, and a Philadelphia company is poised to revolutionize its
production.
Graphene grabbed headlines in 2010, when two physicists from the University of
Manchester in the U.K. won the Nobel Prize after isolating specks of carbon only one
atom thick. Subsequent experiments confirmed what scientists had believed for
decades: The anatomically thin samples -- graphene -- had incomparable physical
qualities.
Flakes were great for research, but as sheets, graphene has the potential to revolutionize
medical science, consumer electronics, and our ability to generate and store renewable
energy.
Meanwhile, across the Atlantic, the seeds of Graphene Frontiers were being sown. A.T.
Charlie Johnson, head of a nanophysics laboratory at the University of Pennsylvania,
and postdoctoral researcher Zhengtang Luo were working together on a novel
production technique. They designed an "Atmospheric Pressure Chemical Vapor
Deposition" (APCVD) -- a process common to the semiconductor industry -- for making
graphene sheets.
Inexpensive, plentiful graphene is poised to send ripples through the supply chain and
enable flexible organic electronics to come to market. This new consumer technology -which uses carbon-based polymers instead of copper or silicone -- promises ultrathin,
flexible, sun-powered consumer devices and sheets of solar panels printed in rolls.
Johnson and Luo's company, Graphene Frontiers, is among the first manufacturers of
commercial-grade sheet graphene in the world. The company began atPenn's UPStart, a
program dedicated to technology commercialization. They eventually hired CEO Mike
Patterson, a Wharton MBA and former SVP of global delivery for Bank of America.
In 2011, iCorps accepted Graphene Frontiers into their first cohort and the company
worked with entrepreneurial giant Steve Blank. In 2012, they opened their headquarters
at the University City Science Center's Port Business Incubator. Graphene Frontiers
receives grants from the National Science Foundations Small Business Innovation
Research Program and has earned an additional $500,000 in angel investment.
"You could do a lot with this material if you could manage to make a lot of it," says
Patterson. "Thats what [Graphene Frontiers] does. We have a way to make large-area
pieces of graphene relatively cheaply."

Graphenes only elementcarbonis everywhere and exists in different allotropes, or

bond formations, including diamond. Structurally, graphene is just graphite (like the
stuff in No. 2 pencils) in a single atomic layer.
"Its a hexagonal lattice thats essentially perfect," explains Patterson. "If you look at it
under an electron microscope it looks like a chain-link fence. Its just carbon arranged in
a specific pattern."
Hidden inside the composition of graphite are submicroscopic platelets of graphene.
The Nobel Prize winners confirmed graphenes existence in 2004 by peeling back the
atomic layers of a graphite block using scotch tape. It was an incredibly simple solution
to a complicated problem.
Currently, standard graphene processes blow apart gaphite, releasing the
submicroscopic shards. The resulting powder is in paints, polymers (plastics) and
batteries.
Graphene Frontiers, on the other hand, "grows" the allotrope. The process begins with a
sheet of copper foil placed inside a furnace. Methane gas is added to the foils surface.
Carbon atoms from the gas adhere to the hot copper and bond to each other laterally,
creating a sheet of graphene -- like ice forming on a pond.
Graphene Frontiers has also developed the first chemical-free technique that cleanly
removes graphene from copper. The method allows for repeated use of a single piece of
foil, a key component for large-scale manufacturing.
"It's really going to rile the entire industry," he says. "What graphene can do is provide a
super thin, conductive layer. Because of graphene, thin, flexible organic electronics are
going to take off."
Currently, Graphene Frontiers sells samples to research and development departments
of universities and corporations, as well as government and military agencies. They
partner with SPI Supplies in West Chester on custom Transmission Electron Microscopy
(TEM) grids, a fine mesh that traps DNA, cellular proteins and molecules inside a slide.
With a coat of graphene, TEM slides are capable of holding these frenetic particles
steady, enabling a new class of research. TEM slides are already generating revenue for
Graphene Frontiers.
The company has entered an undisclosed partnership with a major materials
corporation to help scale up production. By the end of this year, they expect to have a
prototype.
Initially, the larger pieces of sheet graphene will enhance specialty products including
chemical sensors and energy storage units such as supercapacitors. Within three or four
years, consumer tech companies including Google, Apple and Samsung expect to release
a new generation of inexpensive cell phones and tablets that can fold up and tuck inside

a shirt pocket. Graphene Frontiers' goal is to be their supplier.

The market has tremendous potential. By 2018, Graphene Frontiers projects a total
addressable market of $1.2 billion, made up of market segments including energy
storage units (supercapacitors, batteries), thermal management systems, thin film solar
and thin flexible printed display electronics.
To keep pace with that demand, the company is hiring two or three PhD-level
scientists this year. In three to four years, they expect to boast 100-plus
employees -- 50 percent of which will be in Research and Development.
"Graphene was that final missing piece," says Patterson. "It's the first demonstratable
and isolated two-dimensional material -- it has just one single layer of atoms -- and
that's special. In the world of graphene, having anything bigger than a centimeter square
is a big deal. We've already gone to iPad-sized pieces."