Stretchable Gas Barrier Films Using Liquid Metal toward a Highly Deformable Battery

Diels-Alder Network Blends as Self-Healing Encapsulants for Liquid Metal-Based Stretchable Electronics

Two dynamic covalent networks based on the Diels-Alder reaction were blended to exploit the properties of the dissimilar polymer backbones. Furan-functionalized polyether amines based on poly(propylene oxide) (PPO) FD4000 and polydimethylsiloxane (PDMS) FS5000 were mixed in a common solvent and reversibly cross-linked with the same bismaleimide DPBM. The morphology of the phase-separated blends is primarily controlled by the concentration of backbones. Increasing the PDMS content of the blends results in a dilute droplet morphology at 25 wt %, with a growing size and concentration of droplets and the formation of two separate PPO- and PDMS-rich layers at 50 wt %. Further increasing the PDMS content to 75 wt % leads to larger droplets and a thicker layer of the secondary phase. The hydrophobic PDMS phase creates a barrier against water, while the more hydrophilic PPO phase enhances the resistance against oxygen diffusion. Lowering the maleimide-to-furan stoichiometric ratio resulted in a decrease in cross-link density and thus more flexible and stretchable encapsulants. Changes in the stoichiometric ratio also affected the phase morphology due to resulting changes in phase separation and network formation kinetics. Lowering the stoichiometric ratio also resulted in enhanced self-healing properties of 96% at room temperature as a consequence of the increased chain mobility in the blended networks. The self-healing blends were used to encapsulate liquid metal circuits to create stretchable strain sensors with a linear electro-mechanical response without much drift or hysteresis, which could be efficiently recovered by 90% after the damage-healing cycles.

Patterned Liquid-Metal-Enabled Universal Soft Electronics (PLUS-E) for Deformation Sensing on 3D Curved Surfaces

Liquid metals with metallic conductivity and infinitely deformable properties have tremendous potential in the field of conformal electronics. However, most processing methods of liquid metal electronics require sophisticated apparatus or custom masks, resulting in high processing costs and intricate preparation procedures. This study proposes a simple and rapid preparation method for patterned liquid-metal-enabled universal soft electronics (PLUS-E). The utilization of selective adhesion of the liquid metals on stretchable substrates and the adaptive toner mask enables rapid fabrication (<2 s/100 cm2), excellent stretchability (800% strain), and high forming accuracy (100 μm). Benefiting from the adaptive deformation of the substrate and toner mask, PLUS-E can be conformally applied to any shape of 3D surfaces. Besides, the stability of PLUS-E on 3D surfaces is improved by low-fluidity liquid metal composites. The finite element simulation is used to accurately forecast the deformation and resistance changes of the PLUS-E, and it provides guidance for device design and manufacturing. Finally, this method was utilized to develop various sensors for detecting human motion, catheter bending, and balloon expansion. All of them have obtained stable and reliable signal measurements, demonstrating the usefulness of PLUS-E in real-world applications.

High-Accuracy Contact Resistance Measurement Method for Liquid Metal by Considering Current-Density Distribution in Transfer Length Method Measurement

Liquid metals (LMs) are used as stretchable conductors in various stretchable electronic devices. Moreover, such devices using Ga-based LMs have attracted considerable attention. Herein, we propose a method for accurately determining the contact resistance (Rc) between galinstan and Cu electrodes by considering the current-density distribution in transfer length method (TLM) measurement. Conventional TLM measurements assume that the sheet resistance of the metal electrode (Rshe) is negligible compared with that of the object (Rsho), such as Si. However, this assumption may be problematic because the Rsho of Ga-based liquid metals (LMs) is close to the Rshe. Therefore, we developed a method of applying current to each measuring electrode and compared it with the conventional method of applying current to the outer electrodes. Simulation results indicated that Rshe cannot be ignored for galinstan, and the measured resistance in the contact area (RcTotal) included <10% of the Rc component when current was applied to the outer electrodes. In contrast, RcTotal included the entire Rc component when current was applied to each electrode. Furthermore, we found that the volume resistances of the object and electrode included in RcTotal cannot be ignored. Therefore, for accurate measurement, current must be applied to each electrode, and Rc must be determined from the intersections of the measured and simulated RcTotal. The obtained contact resistivity (ρc), i.e., the contact resistance per unit contact area, was 0.115 mΩ·mm2. The maximum error was 0.085 mΩ·mm2, which was lower than the ρc of the solders (≥10-1 mΩ·mm2) with the lowest ρc among the electrical interface materials between the electronic components and wiring. This study provides valuable insight into the Rc measurement of LMs, along with new opportunities for the development of stretchable electronics using LMs.

High-Precision Stretchable Ionic Temperature Sensor Passivated with a Liquid Metal/Block Copolymer Multilayer Film

Moisture barriers are essential for ionic sensors because moisture has a direct impact on the stability and reliability of electrochemical properties. So far, stretchable moisture barriers that can maximize the advantage of using deformable ion gel as the active material have been rarely investigated and remain as a technological challenge. This study proposes a four-layer (4L) stretchable moisture barrier alternatively composed of a poly(styrene-isobutylene-styrene) copolymer (SiBS) film (2 μm in thickness) and a eutectic gallium-indium liquid metal (LM) film (1 μm in thickness). This multilayer barrier has a low water permeability of 9.09 × 10^-20 m²/Pa s at 50% uniaxial strain (ε) and retains the barrier properties at repeated stretchable cycles at ε = 50%. This study demonstrates a skin-attached precise ion gel-based temperature sensor that is independent of moisture change (even dipping in water) and body motions.

Liquid metal-based soft, hermetic, and wireless-communicable seals for stretchable systems

Soft materials tend to be highly permeable to gases, making it difficult to create stretchable hermetic seals. With the integration of spacers, we demonstrate the use of liquid metals, which show both metallic and fluidic properties, as stretchable hermetic seals. Such soft seals are used in both a stretchable battery and a stretchable heat transfer system that involve volatile fluids, including water and organic fluids. The capacity retention of the battery was ~72.5% after 500 cycles, and the sealed heat transfer system showed an increased thermal conductivity of approximately 309 watts per meter-kelvin while strained and heated. Furthermore, with the incorporation of a signal transmission window, we demonstrated wireless communication through such seals. This work provides a route to create stretchable yet hermetic packaging design solutions for soft devices.