Screen-printed paper-based thermocouples with carbon and silver single and multi-layers

Abstract This paper explores the development of paper-based thermocouples fabricated using various carbon and silver thick layers to create an eco-friendly, cost-effective, and flexible temperature-sensing device. Using screen-printing technique, thermocouples with different layer configurations and drying conditions were tested for thermoelectric voltage response and sensitivity under varying temperature differences (Δ T ). The highest performance was observed in narrow, multilayered thermocouples with ED7500 carbon paste, achieving 257 µ V at Δ T = 45 °C and a sensitivity of 5.44 µ V °C ⁻¹ . Comparisons showed that narrow designs and increased layer counts significantly enhanced sensitivity, while carbon pastes such as ED5020 and 26–8203 exhibited lower responses (typically below 2.45 µ V °C ⁻¹ ). Long-term climatic aging and thermal shocks testing revealed that controlled environmental exposure improved thermoelectric performance, but excessive cycling beyond 1500 shocks resulted in structural degradation. The results indicate that printed paper-based thermocouples are a viable alternative to conventional metal-based sensors, offering lightweight, flexible, and sustainable solutions for applications in wearable sensors, environmental monitoring, and printed electronics.