Developing the Surface Chemistry of Transparent Butyl Rubber for Impermeable Stretchable Electronics

Transfer Printing of Ordered Plasmonic Nanoparticles at Hard and Soft Interfaces with Increased Fidelity and Biocompatibility Supports a Surface Lattice Resonance

Transfer printing, the relocation of structures assembled on one surface to a different substrate by adjusting adhesive forces at the surface-substrate interface, is widely used to print electronic circuits on biological substrates like human skin and plant leaves. The fidelity of original structures must be preserved to maintain the functionality of transfer-printed circuits. This work developed new biocompatible methods to transfer a nanoscale square lattice of plasmon resonant nanoparticles from a lithographed surface onto leaf and glass substrates. The fidelity of the ordered nanoparticles was preserved across a large area in order to yield, for the first time, an optical surface lattice resonance on glass substrates. To effect the transfer, interfacial adhesion was adjusted by using laser induction of plasmons or unmounted adhesive. Optical and confocal laser scanning microscopy showed that submicron spacing of the square lattice was preserved in ≥90% of transfer-printed areas up to 4 mm2. Up to 90% of ordered nanoparticles were transferred, yielding a surface lattice resonance measured by transmission UV-vis spectroscopy.

Reliability of printed stretchable electronics based on nano/micro materials for practical applications

Recent decades have witnessed the booming development of stretchable electronics based on nano/micro composite inks. Printing is a scalable, low-cost, and high-efficiency fabrication tool to realize stretchable electronics through additive processes. However, compared with conventional flexible electronics, stretchable electronics need to experience more severe mechanical deformation which may cause destructive damage. Most of the reported works in this field mainly focus on how to achieve a high stretchability of nano/micro composite conductors or single working modules/devices, with limited attention given to the reliability for practical applications. In this minireview, we summarized the failure modes when printing stretchable electronics using nano/micro composite ink, including dysfunction of the stretchable interconnects, the stress-concentrated rigid-soft interfaces for hybrid electronics, the vulnerable vias upon stretching, thermal accumulation, and environmental instability of stretchable materials. Strategies for tackling these challenges to realize reliable performances are proposed and discussed. Our review provides an overview on the importance of reliable, printable, and stretchable electronics, which are the key enablers in propelling stretchable electronics from fancy demos to practical applications.

Protocol for fabricating electroless nickel immersion gold strain sensors on nitrile butadiene rubber gloves for wearable electronics

This protocol describes the fabrication of patterned conductive gold films on nitrile butadiene rubber (NBR) gloves for wearable strain sensors using electroless nickel immersion gold (ENIG) plating, a solution-based metallization technique. The resulting NBR/ENIG films are strain sensitive; resistance measurements of a patterned sensing array can be used to map human hand motions. This protocol also describes challenges related to the ENIG process and troubleshooting steps to achieve conformal gold films for strain sensing over a large working range.

For complete details on the use and execution of this protocol, please refer to Mechael et al. (2021).

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Detailed protocol to prepare strain sensors on nitrile butadiene rubber (NBR) gloves

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Procedure to activate NBR for electroless nickel immersion gold (ENIG) metallization

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Patterned ENIG deposition by airbrushing a commercially available latex emulsion

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Tensile strain increases the resistance of the ENIG film for wearable motion sensing

Flexible plasmonic modulators induced by the thermomechanical effect

Reconfigurable plasmon-based flexible devices, composed of artificial plasmonic nanostructures on stretchable substrates, show great promise for dynamic functionalities such as tunability, switching and modulation of electromagnetic waves. Here, we theoretically proposed and experimentally demonstrated a simple and efficient flexible plasmonic modulator based on an array of gold nanostructures on a poly(dimethylsiloxane) (PDMS) substrate. Arising from the current-induced local Joule heat, the local expansion of the PDMS substrate widens the gap distances between the neighboring gold wires, which results in a spectral shift of the plasmon resonance. The experimental results show that the plasmon resonance has a blue-shift of 39 nm under a total power consumption of only 10.5 mW, which results in a high modulation depth of up to 30.5% for the modulator. Such a low power consumption can be ascribed to the small active area and excellent thermal isolation of the PDMS. The optical and thermomechanical responses were confirmed and understood by the electromagnetic and thermomechanical co-simulations based on the finite-difference time-domain and finite-element methods. This novel mechanism to manipulate light provides new opportunities for active optical components and integrated circuits.

Repeatable and metal-independent nanotransfer printing based on metal oxidation for plasmonic color filters

Many recently developed nanotransfer printing techniques have received much attention because of their simplicity and low cost. In addition, such techniques are suitable for fabricating nano/microscale sensors, optical elements, and electrical devices. However, conventional nanotransfer printing methods are time-consuming, cannot be easily used over large areas or with several different materials, and are not suitable for repeatedly transferring various materials onto the same substrate or a curved surface. Herein, a new nanotransfer printing method is introduced based on the oxidation of various metals and the formation of covalent bonds between spin- and spray-coatable adhesives and the chosen metal at low temperatures. These strong covalent bonds allow the fast transfer of the deposited materials from a polymer stamp without additional processing. A major advantage of this process is that it is metal-independent; nanowires of various metals are successfully transferred from the polymer stamp because strong covalent bonds form instantaneously between the metal and an adhesive-coated substrate. Moreover, this nanotransfer process can be used repeatedly to fabricate large-scale color filters from smaller areas of nanowires, regardless of the metal type and nanostructure orientation. Furthermore, plasmonic color filters composed of nanohole arrays can be obtained on both flat and curved surfaces.

Stretchable Seal

Many stretchable electronic devices require stretchable hermetic seals. However, stretchability and permeability are inextricably linked at the molecular level: stretchable, low-permeability materials do not exist. We collect data for the permeation of water and oxygen in many materials and describe the scaling relations for both flat and wrinkled seals. Whereas flat seals struggle to fulfill the simultaneous requirements of stretchability, low stiffness, and low transmissibility, wrinkled seals can fulfill them readily. We further explore the behavior of wrinkled seals under cyclic stretch using aluminum, polyethylene, and silica films on elastomer substrates. The wrinkled aluminum develops fatigue cracks after a small number of cycles, but the wrinkled polyethylene and silica maintain low transmissibility after 10 000 cycles of tensile strain.

Wearable and Washable Conductors for Active Textiles

The emergence of stretchable electronics and its potential integration with textiles have highlighted a challenge: Textiles are wearable and washable, but electronic devices are not. Many stretchable conductors have been developed to enable wearable active textiles, but little has been done to make them washable. Here we demonstrate a new class of stretchable conductors that can endure wearing and washing conditions commonly associated with textiles. Such a conductor consists of a hydrogel, a dissolved hygroscopic salt, and a butyl rubber coating. The hygroscopic salt enables ionic conduction and matches the relative humidity of the hydrogel to the average ambient relative humidity. The butyl rubber coating prevents the loss and gain of water due to the daily fluctuation of ambient relative humidity. We develop the chemistry of dip-coating the butyl rubber onto the hydrogel, using silanes to achieve both the cross-link of the butyl rubber and the adhesion between the butyl rubber and the hydrogel. We test the endurance of the conductor by soaking it in detergent while stretching it cyclically and by machine-washing it. The loss of water and salt is minimal. It is hoped that these conductors open applications in healthcare, entertainment, and fashion.

Triplet transport in thin films: fundamentals and applications

An overview of experimental and theoretical work on triplet energy transfer, with a focus on triplet transport in thin films.