Spray coating of crack templates for the fabrication of transparent conductors and heaters on flat and curved surfaces

Flexible Embedded Metal Meshes by Sputter-Free Crack Lithography for Transparent Electrodes and Electromagnetic Interference Shielding

A facile and novel fabrication method is demonstrated for creating flexible poly(ethylene terephthalate) (PET)-embedded silver meshes using crack lithography, reactive ion etching (RIE), and reactive silver ink. The crack width and spacing in a waterborne acrylic emulsion polymer are controlled by the thickness of the polymer and the applied stress due to heating and evaporation. Our innovative fabrication technique eliminates the need for sputtering and ensures stronger adhesion of the metal meshes to the PET substrate. Crack trench depths over 5 μm and line widths under 5 μm have been achieved. As a transparent electrode, our flexible embedded Ag meshes exhibit a visible transmission of 91.3% and sheet resistance of 0.54 Ω/sq as well as 93.7% and 1.4 Ω/sq. This performance corresponds to figures of merit (σDC/σOP) of 7500 and 4070, respectively. For transparent electromagnetic interference (EMI) shielding, the metal meshes achieve a shielding efficiency (SE) of 42 dB with 91.3% visible transmission and an EMI SE of 37.4 dB with 93.7% visible transmission. We demonstrate the highest transparent electrode performance of crack lithography approaches in the literature and the highest flexible transparent EMI shielding performance of all fabrication approaches in the literature. These metal meshes may have applications in transparent electrodes, EMI shielding, solar cells, and organic light-emitting diodes.

A thin-film polymer heating element with a continuous silver nanowires network embedded inside

This study presents a method for fabricating a film-based heating element using a polymer material with an array of intersecting conductive elements embedded within it. Track-etched membranes (TM) with a thickness of 10μm were used as the template, and their pores were filled with metal, forming a three-dimensional grid. Due to the unique manufacturing process of TM, the pores inside intersect with each other, allowing for contacts between individual nanowires (NWs) when filled with metal. Experimental results demonstrated that filling the TM pores with silver allows for heating temperatures up to 78 degrees without deformation or damage to the heating element. The resulting flexible heating element can be utilized in medical devices for heating purposes or as a thermal barrier coating.

Mathematical Model-Assisted Ultrasonic Spray Coating for Scalable Production of Large-Sized Solid Oxide Electrochemical Cells

Thin solid oxide films are crucial for developing high-performance solid oxide-based electrochemical devices aimed at decarbonizing the global energy system. Among various methods, ultrasonic spray coating (USC) can provide the throughput, scalability, quality consistency, roll-to-roll compatibility, and low material waste necessary for scalable production of large-sized solid oxide electrochemical cells. However, due to the large number of USC parameters, systematic parameter optimization is required to ensure optimal settings. However, the optimizations in previous literature are either not discussed or not systematic, facile, and practical for scalable production of thin oxide films. In this regard, we propose an USC optimization process assisted with mathematical models. Using this method, we obtained optimal settings for producing high-quality, uniform 4 × 4 cm² oxygen electrode films with a consistent thickness of ∼27 μm in 1 min in a facile and systematic way. The quality of the films is evaluated at both micrometer and centimeter scales and meets desirable thickness and uniformity criteria. To validate the performance of USC-fabricated electrolytes and oxygen electrodes, we employ protonic ceramic electrochemical cells, which achieve a peak power density of 0.88 W cm^-2 in the fuel cell mode and a current density of 1.36 A cm^-2 at 1.3 V in the electrolysis mode, with minimal degradation over a period of 200 h. These results demonstrate the potential of USC as a promising technology for scalable production of large-sized solid oxide electrochemical cells.

Cracked Film Lithography with CuGaOx Buffers for Bifacial CdTe Photovoltaics

Bifacial CdTe solar cells with greater power density than the monofacial baselines are demonstrated by using a CuGaO_x rear interface buffer that passivates while reducing sheet resistance and contact resistance. Inserting CuGaO_x between the CdTe and Au increases mean power density from 18.0 ± 0.5 to 19.8 ± 0.4 mW cm^-2 for one sun front illumination. However, coupling CuGaO_x with a transparent conductive oxide leads to an electrical barrier. Instead, CuGaO_x is integrated with cracked film lithography (CFL)-patterned metal grids. CFL grid wires are spaced narrowly enough (≈10 µm) to alleviate semiconductor resistance while retaining enough passivation and transmittance for a bifacial power gain: bifacial CuGaO_x /CFL grids generate 19.1 ± 0.6 mW cm^-2 for 1 sun front + 0.08 sun rear illumination and 20.0 ± 0.6 mW cm^-2 at 1 sun front + 0.52 sun rear-the highest reported power density at field albedo conditions for a scaled polycrystalline absorber.

A crack templated copper network film as a transparent conductive film and its application in organic light-emitting diode

In this paper, a highly transparent, low sheet resistance copper network film fabricated by a crack template, which made by drying an acrylic based colloidal dispersion. The fabricated copper network film shows excellent optoelectronic performances with low sheet resistance of 13.4 Ω/sq and high optical transmittance of 93% [excluding Polyethylene terephthalate (PET) substrate] at 550 nm. What’s more, the surface root mean square of the copper network film is about 4 nm, and the figure of merit is about 380. It’s comparable to that of conventional indium tin oxide thin film. The repeated bending cycle test and adhesive test results confirm the reliability of the copper network film. As a transparent conductive film, the copper network film was used as an anode to prepare organic light-emitting diode (OLED). The experiment results show that the threshold voltage of the OLED is less than 5 V and the maximum luminance is 1587 cd/m2.

Smart low interfacial toughness coatings for on-demand de-icing without melting

Ice accretion causes problems in vital industries and has been addressed over the past decades with either passive or active de-icing systems. This work presents a smart, hybrid (passive and active) de-icing system through the combination of a low interfacial toughness coating, printed circuit board heaters, and an ice-detecting microwave sensor. The coating's interfacial toughness with ice is found to be temperature dependent and can be modulated using the embedded heaters. Accordingly, de-icing is realized without melting the interface. The synergistic combination of the low interfacial toughness coating and periodic heaters results in a greater de-icing power density than a full-coverage heater system. The hybrid de-icing system also shows durability towards repeated icing/de-icing, mechanical abrasion, outdoor exposure, and chemical contamination. A non-contact planar microwave resonator sensor is additionally designed and implemented to precisely detect the presence or absence of water or ice on the surface while operating beneath the coating, further enhancing the system's energy efficiency. Scalability of the smart coating is demonstrated using large (up to 1 m) iced interfaces. Overall, the smart hybrid system designed here offers a paradigm shift in de-icing that can efficiently render a surface ice-free without the need for energetically expensive interface melting.

Directly Printed Embedded Metal Mesh for Flexible Transparent Electrode via Liquid Substrate Electric-Field-Driven Jet

Flexible transparent electrodes (FTEs) with embedded metal meshes play an indispensable role in many optoelectronic devices due to their excellent mechanical stability and environmental adaptability. However, low-cost, simple, efficient, and environmental friendly integrated manufacturing of high-performance embedded metal meshes remains a huge challenge. Here, a facile and novel fabrication method is proposed for FTEs with an embedded metal mesh via liquid substrateelectric-field-driven microscale 3D printing process. This direct printing strategy avoids tedious processes and offers low-cost and high-volume production, enabling the fabrication of high-resolution, high-aspect ratio embedded metal meshes without sacrificing transparency. The final manufactured FTEs with 80 mm × 80 mm embedded metal mesh offers excellent optoelectronic performance with a sheet resistance (Rs ) of 6 Ω sq-1 and a transmittance (T) of 85.79%. The embedded metal structure still has excellent mechanical stability and good environmental suitability under different harsh working conditions. The practical feasibility of the FTEs is successfully demonstrated with a thermally driven 4D printing structure and a resistive transparent strain sensor. This method can be used to manufacture large areas with facile, high-efficiency, low-cost, and high-performance FTEs.

3D Printed High Performance Silver Mesh for Transparent Glass Heaters through Liquid Sacrificial Substrate Electric-Field-Driven Jet

Transparent glass with metal mesh is considered a promising strategy for high performance transparent glass heaters (TGHs). However, the realization of simple, low-cost manufacture of high performance TGHs still faces great challenges. Here, a technique for the fabrication of high performance TGHs is proposed using liquid sacrificial substrate electric-field-driven (LS-EFD) microscale 3D printing of thick film silver paste. The liquid sacrificial substrate not only significantly improves the aspect ratio (AR) of silver mesh, but also plays a positive role in printing stability. The fabricated TGHs with a line width of 35 µm, thickness of 12.3 µm, and pitch of 1000 µm exhibit a desirable optoelectronic performance with sheet resistance (R_s ) of 0.195 Ω sq^-1 and transmittance (T) of 88.97%. A successful deicing test showcases the feasibility and practicality of the manufactured TGHs. Moreover, an interface evaporator is developed for the coordination of photothermal and electrothermal systems based on the high performance TGHs. The vapor generation rate of the device reaches 10.69 kg m^-2 h^-1 with a voltage of 2 V. The proposed technique is a promising strategy for the cost-effective and simple fabrication of high performance TGHs.

Flexible Transparent Heater Fabricated from Spray-Coated In:ZnO/Ag-NWs/In:ZnO Multilayers on Polyimide Foil

A flexible transparent heater is presented, based on an all-sprayed composite architecture of indium-doped zinc oxide (IZO) layers that sandwich a network of silver nanowires, on a polyimide-foil substrate. This architecture could be materialized through the development of a low-temperature (240 °C) spray-pyrolysis process for the IZO layers, which is compatible with the thermal stability of the transparent polyimide substrate and allows for the formation of compact and transparent layers, without precipitates. The IZO layers entirely embed the silver nanowires, offering protection against environmental degradation and decreasing the junction resistance of the nanowire network. The resulting transparent heaters have a high mean transmittance of 0.76 (including the substrate) and sheet resistance of 7.5 Ω/sq. A steady-state temperature of ~130 °C is achieved at an applied bias of 3.5 V, with fast heater response times, with a time constant of ~4 s The heater is mechanically stable, reaching or surpassing 100 °C (at 3.5 V), under tensile, respectively, compressive-bending stress. This work shows that high-performance transparent heaters can be fabricated using all-sprayed oxide/silver-nanowire composite coatings, that are compatible with large-scale and low-cost production.

Time Evolution and Spatial Hierarchy of Crack Patterns

Cracks generated due to desiccation of wet colloidal systems are ubiquitous, examples being nanomaterial films, painted walls, cemented floors, mud fields, river beds, and even giant rocks. In all such cases, crack patterns are often appreciably similar but for the length and time scales, which can be widely differing. In this work, we have examined the crack formation more closely to see if there exists some generality with regard to the length scale of parameters and the formation time. Specifically, using a commonly used colloidal dispersion and optimized conditions to form polygonal network patterns rather than isolated cracks (films of subcritical thickness), we have studied the time evolution of the pattern parameters, the area occupied by the cracks, their lengths, and the widths. As is well known, initially, a network of cracks forms, which we term as the primary generation, followed by interconnecting cracks inside the polygonal regions (secondary) and, later, cracks spreading in local regions (tertiary). We find that the area and the width increase nearly linearly with time with the change in the slope corresponding to the change in the generation. When normalized with respect to the final values, the trends obtained for different film thicknesses overlap, the only exception being the pattern containing unconnected cracks. Thus, the time evolution of cracks is shown to be predictable based on width filtering. Including the angle between cracks as further input into the recursive model, the possibility of identifying the hierarchy of crack segments is also shown. The approach may be useful in determining the age, authenticity, and details of old paintings, understanding the stress profile of geological rocks, and analyzing various natural and manmade hierarchical structures.

Strain-Tunable Microfluidic Devices with Crack and Wrinkle Microvalves for Microsphere Screening and Fluidic Logic Gates

Mechanical instabilities in soft materials have led to the formation of unique surface patterns such as wrinkles and cracks for a wide range of applications that are related to surface morphologies and their dynamic tuning. Here, we report a simple yet effective strategy to fabricate strain-tunable crack and wrinkle microvalves with dimensions responding to the applied tensile strain. The crack microvalves initially closed before stretching are opened as the tensile strain is applied, whereas the wrinkle microvalves exhibit the opposite trend. Next, the performance of crack and wrinkle microvalves is characterized. The design predictions on the bursting pressure of microvalves and others from the theory agree reasonably well with the experimental measurements. The microfluidic devices with strain-tunable crack and wrinkle microvalves have then been demonstrated for microsphere screening and programmable microfluidic logic devices. The demonstrated microfluidic devices complement the prior studies to open up opportunities in microparticle/cell manipulations, fluidic operations, and biomedicine.

Well-rounded devices: the fabrication of electronics on curved surfaces - a review

With the arrival of the internet of things and the rise of wearable computing, electronics are playing an increasingly important role in our everyday lives. Until recently, however, the rigid angular nature of traditional electronics has prevented them from being integrated into many of the organic, curved shapes that interface with our bodies (such as ergonomic equipment or medical devices) or the natural world (such as aerodynamic or optical components). In the past few years, many groups working in advanced manufacturing and soft robotics have endeavored to develop strategies for fabricating electronics on these curved surfaces. This is their story. In this work, we describe the motivations, challenges, methodologies, and applications of curved electronics, and provide a outlook for this promising field.

Cracking to curling transition in drying colloidal films

Drying-induced cracking is widely encountered in nature and is of fundamental interest in industrial applications. During desiccation, the evolution of water content is nonlinear. Considering the inhomogeneous procedure of desiccation, it is worth considering whether water content will affect the crack pattern formation. To address this concern, in this paper, we report an experimental investigation on the effect of water content on the failure mode in drying colloidal films. A distinct failure transition from random cracking to curling is found when the initial water content increases gradually. When the water content is below a critical value for given film thickness, random desiccation cracking driven by shrinkage is observed. Beyond this critical water content, the film curls with the advent of several main cracks. It is also found that the critical water content corresponding to the transition point depends on the film thickness. In order to qualitatively interpret the experimental observation, a theoretical model is established by adopting the fracture mechanics based on the energy method. The model is found to agree well with the experimental results, elucidating the effects of initial water content on the crack patterns and the transition of failure modes.

Patterning Metal Grids for GaAs Solar Cells with Cracked Film Lithography: Quantifying the Cost/Performance Tradeoff

We introduce cracked film lithography (CFL) as a way to reduce the cost of III-V photovoltaics (PV). We spin-coat nanoparticle suspensions onto GaAs thin-film device stacks. The suspensions dry in seconds, forming crack networks that we use as templates through which to electroplate the solar cells' front metal grids. For the first time, we show that heating the crack template allows it to flow and refill cracks, which decreases crack footprint and improves final grid transmittance. We demonstrate 24.7%-efficient single-junction GaAs solar cells using vacuum-free CFL grids. These devices are only 1.7% (absolute) less efficient than the baseline grids patterned by photolithography with the loss mostly resulting from the reduced transparency of the CFL pattern. Additional optimization could decrease this difference. Initial cost modeling suggests that CFL is more scalable than photolithography: In particular, CFL's lower materials and equipment costs could greatly reduce the levelized cost of electricity of III-V PV at scale, a potential step toward terrestrial deployment.

Innovative Approach to Photo-Chemiresistive Sensing Technology: Surface-Fluorinated SnO2 for VOC Detection

Transparent electronics continues to revolutionize the way we perceive futuristic devices to be. In this work, we propose a technologically advanced volatile organic compound (VOC) sensor in the form of a thin-film transparent display fabricated using fluorinated SnO₂ films. A solution-processed method for surface fluorination of SnO₂ films using Selectfluor as a fluorinating agent has been developed. The doped fluorine was optimized to be <1%, resulting in a significant increase in conductivity and reduction in persistent photoconductivity accompanied by a faster decay of the photogenerated charge carriers. A combination of these modified properties, together with the intrinsic sensing ability of SnO₂, was exploited in designing a transparent display sensor for ppm-level detection of VOCs at an operating temperature of merely 150 °C. Even a transparent metal mesh heater is integrated with the sensor for ease of operation, portability, and less power usage. A sensor reset method is developed while shortening the UV exposure time, enabling complete sensor recovery at low operating temperatures. The sensor is tested toward a variety of polar and nonpolar VOCs (amines, alcohols, carbonyls, alkanes, halo-alkanes, and esters), and it exhibits an easily differentiable response with sensitivity in line with the electron-donating tendency of the functional group present. This work opens up the door for multiplexed sensor arrays with the ability to detect and analyze multiple VOCs with specificity.

Recent progress in controlled nano/micro cracking as an alternative nano-patterning method for functional applications

Generally, cracking occurs for many reasons connected to uncertainties and to the non-uniformity resulting from intrinsic deficiencies in materials or the non-linearity of applied external (thermal, mechanical, etc.) stresses. However, recently, an increased level of effort has gone into analyzing the phenomenon of cracking and also into methods for controlling it. Sophisticated manipulation of cracking has yielded various cutting-edge technologies such as transparent conductors, mechanical sensors, microfluidics, and energy devices. In this paper, we present some of the recent progress that has been made in controlling cracking by giving an overview of the fabrication methods and working mechanisms used for various mediums. In addition, we discuss recent progress in the various applications of methods that use controlled cracking as an alternative to patterning tools.

Macroscopic Nonuniformities in Metal Grids Formed by Cracked Film Lithography Result in 19.3% Efficient Solar Cells

Cracked film lithography (CFL) is an emerging method for patterning transparent conductive metal grids. CFL can be vacuum- and Ag-free, and it forms more durable grids than nanowire approaches. In spite of CFL's promising transmittance/grid sheet resistance/wire spacing tradeoffs, previous solar cell demonstrations have had relatively low performance. This work introduces macroscopic nonuniformities in the grids to improve the short-circuit current density/fill factor tradeoff in small area Cu(In,Ga)Se₂ cells. The performance of optimized baseline grids is matched by CFL grids with microscopic openings and macroscopic patterns, culminating in a 19.3% efficient cell. Simulations show that uniform CFL grids are enhanced by patterning because it leads to better balance among shadowing, grid resistance, and transparent conductive oxide resistance losses. Thin-film module efficiency calculations are performed to highlight the performance gains that metal grids can enable by eliminating the transparent conductive oxide losses and widening monoliths. Adding the patterned CFL grids demonstrated in this work to CIGS modules is predicted to reach 0.7% higher efficiency (absolute) than screen-printed grids.

Active and Deformable Organic Electronic Devices based on Conductive Shape Memory Polyimide

Smart, deformable, and transparent electrodes are a significant part of flexible optoelectronic devices. In this work, a novel approach to making highly transparent, smooth, and conductive shape memory polyimide hybrids has been proposed. Colorless shape memory polyimide (CSMPI) with high optical transparency and high heat resistance is served as the substrate for flexible electronic devices for the first time. A hybrid (Au/Ag) metal grid electrode embedded in CSMPI (BMG/CSMPI) is first fabricated via self-cracking template and solution-coating, the advantages of which include ultrasmooth surface, superior mechanical flexibility and durability, strong surface adhesion, and excellent chemical stability due to the unique embedded hybrid structure. The resulting white polymer light emitting diodes (WPLEDs) based on BMG/CSMPI with shape memory effect are active and deformable, and are converted from 2D device into 3D devices depending on its variable stiffness characteristics. The deformed 3D devices could actively recover to the original shape upon heating. Furthermore, ultrathin and flexible 3D optoelectronic devices fabricated using shape memory polymers can promote the development of advanced optoelectronic applications in the future.

Fundamentals of Using Cracked Film Lithography to Pattern Transparent Conductive Metal Grids for Photovoltaics

The fundamentals of using cracked film lithography (CFL) to fabricate metal grids for transparent contacts in solar cells were studied. The underlying physics of drying-induced cracks were well-predicted by an empirical correlation relating crack spacing to capillary pressure. CFL is primarily controlled by varying the crack template thickness, which establishes a three-way tradeoff between the areal density of cracks, crack width, and spacing between cracks, which in turn determine final grid transmittance, grid sheet resistance, and the semiconductor resistance for a given solar cell. Since CFL uses a lift-off process, an additional constraint is that the metal thickness must be less than 1/3 of the crack template thickness. The transmittance/grid sheet resistance/wire spacing tradeoffs measured in this work were used to calculate solar cell performance: CFL-patterned grids should outperform screen-printed grids for narrow cells (0.5-2 cm wide) and/or cells with high semiconductor sheet resistance (≥100 Ω/sq), making CFL attractive for monolithically integrated thin-film photovoltaic modules.

Natural Carbon By-Products for Transparent Heaters: The Case of Steam-Cracker Tar

Steam-cracker tar (SCT) is a by-product of ethylene production that is in massive quantities globally (>150 × 10⁶ tons per year). With few useful applications, the production of unwanted SCT leads to the need for its costly disposal or burning at the boiler plant. The discovery of new uses for SCT would therefore bring both economic and environmental benefits, although, to date, efforts toward employing SCT in diverse applications have been limited, and progress is further hampered by a lack of understanding of the material itself. Although complex and highly heterogeneous in nature, the molecular composition of SCT has the potential to serve as a diverse and tunable feedstock for wide-ranging applications. Here, a simple solution-processing method for SCT that allows its conductivity and optical properties to be controlled over orders of magnitude is reported. Here, by way of example, the focus is on the production of transparent conductive thin films, which exhibit a wide range of transparencies (23-93%) and sheet resistances (2.5 Ω □^-1 to 1.2 kΩ □^-1 ) that are tuned by a combination of solution concentration and thermal annealing. As transparent Joule heaters, even without optimization, these SCT devices show competitive performance compared to established technologies such as those based on reduced graphene oxide, and surpass the temperature stability limit of other materials. Furthermore, it is demonstrated that laser annealing can be used to process the SCT films and directly pattern transparent heaters on an arbitrary substrate. These results highlight the potential of SCT as a feedstock material for electronic applications and suggest that broader classes of either naturally occurring carbon or produced carbonaceous by-products could prove useful in a range of applications.

Scalable Manufacturing of Single Nanowire Devices Using Crack-Defined Shadow Mask Lithography

Single nanowires (NWs) have a broad range of applications in nanoelectronics, nanomechanics, and nanophotonics, but, to date, no technique can produce single sub-20 nm wide NWs with electrical connections in a scalable fashion. In this work, we combine conventional optical and crack lithographies to generate single NW devices with controllable and predictable dimensions and placement and with individual electrical contacts to the NWs. We demonstrate NWs made of gold, platinum, palladium, tungsten, tin, and metal oxides. We have used conventional i-line stepper lithography with a nominal resolution of 365 nm to define crack lithography structures in a shadow mask for large-scale manufacturing of sub-20 nm wide NWs, which is a 20-fold improvement over the resolution that is possible with the utilized stepper lithography. Overall, the proposed method represents an effective approach to generate single NW devices with useful applications in electrochemistry, photonics, and gas- and biosensing.

Flexible transparent film heaters using a ternary composite of silver nanowire, conducting polymer, and conductive oxide

Scientific and technological advances in transparent conductive electrodes improve the heating performance of flexible transparent film heaters (TFHs), which can be utilized for various applications as defrosters and heaters. To achieve high performance as well as practical TFHs, several conditions, such as high optical transmittance, low electrical resistance, heating uniformity, and operational stability in various environmental conditions should be satisfied. However, due to the trade-offs between optical transmittance and electrical resistance, it is not easy to fulfill all the requirements concurrently. Here we report flexible TFHs using a ternary composite of silver nanowire (AgNW), conducting polymer (i.e., poly[3,4-ethylenedioxythiophene]:polystyrene sulfonate [PEDOT:PSS]), and a thin conductive oxide (i.e., indium tin oxide [ITO]) layer, exhibiting higher performance in terms of the maximum heating temperature (>110 °C), operational stability, mechanical flexibility, and optical transmittance (95% at 550 nm), compared to pristine AgNW-based TFHs. We also demonstrated the stable operation of the AgNW–PEDOT:PSS/ITO TFHs soaked in water, showing excellent environmental stability. To analyse the fundamental mechanisms for the improved performance of the AgNW–PEDOT:PSS/ITO TFHs, we investigated the progress of joule heating using a device simulator, and found that the improvement originated not only from reduced electrical resistance but also from enhanced heat dissipation with PEDOT:PSS and ITO. We anticipate that our analysis and results will be helpful for further development of practical flexible TFHs.

A high-performance flexible thin film heater using AgNW–PEDOT:PSS/ITO, exhibiting stable operation in water.

Solution-Assembled Ordered Grids Constructed with Silver Nanowires as Transparent Conductive Electrodes

The transparent conductive electrodes (TCEs) composed of silver nanowires (Ag NWs) have shown promising applications recently. In this study, we propose a solution-assembled process to obtain the pattern controllable and uniform-ordered Ag NW grid TCEs by combining with the lithographic technique. The transmittance of Ag NW grid TCEs is controlled by the pattern of grids, but its sheet resistance can be tuned by the diameter of Ag NWs in the grids. As the pattern of grids is fixed, conductive property will improve with the decline of the diameter of Ag NWs. This is a new and efficient strategy to resolve the trade-off between optical transmittance and conductive properties of the random metal nanowire networks for optoelectronic devices.

Flexible Transparent Conductive Film Based on Random Networks of Silver Nanowires

We synthesized silver nanowires (AgNWs) with a mean diameter of about 120 nm and 20⁻70 μm in length using a polyol process. The flexible transparent conductive AgNWs films were prepared using the vacuum filtration-transferring process, in which random AgNWs networks were transferred to a polyethylene terephthalate (PET) substrate after being deposited on mixed cellulose esters (MCEs). Furthermore, the photoelectric and mechanical properties of the AgNWs films were studied. The scanning electron microscopy images show that the AgNWs randomly, uniformly distribute on the surface of the PET substrate, which indicates that the AgNWs structure was preserved well after the transfer process. The film with 81% transmittance at 550 nm and sheet resistance about 130 Ω·sq-1 can be obtained. It is sufficient to be used as a flexible transparent conductive film. However, the results of the bending test and tape test show that the adhesion of AgNWs and PET substrate is poor, because the sheet resistance of film increases during the bending test and tape test. The 0.06 W LED lamp with a series fixed on the surface of the AgNWs-PET electrode with conductive adhesive was luminous, and it was still luminous after bent.

Nickel-enhanced silver nanowire-based transparent heater with large size

An effective process for homogeneous electrodeposition of nickel was developed to improve the performance of silver nanowire-based transparent heaters (AgNW-THs). After electroplating Ni, the silver nanowires are uniformly coated by a layer Ni with 20-40 nm thickness, which has a small effect on the device transmittance, but significantly enhances its conductivity. Most excitingly, the nickel shell leads to a great increase of the temperature toleration of the AgNW-THs. A transparent tubular heater with large size of 3 cm in diameter and 20 cm in length is successfully fabricated, showing excellent heating properties in that the steady-state temperature can reach 284.3 °C and there is minimal variance in temperature after 10 heating cycles, and by using this tube, red Cu powder was oxidized into black CuO in a short time, which was visually observed. Additionally, two other shapes of transparent heaters with large size were constructed for dehydration of CuSO4·5H2O and burning of red phosphorus, respectively. This kind of transparent heater has wide applications requiring high transmittance, excellent temperature toleration and large size, especially for teaching experiment apparatus in a visual model.

Emerging Novel Metal Electrodes for Photovoltaic Applications

Emerging novel metal electrodes not only serve as the collector of free charge carriers, but also function as light trapping designs in photovoltaics. As a potential alternative to commercial indium tin oxide, transparent electrodes composed of metal nanowire, metal mesh, and ultrathin metal film are intensively investigated and developed for achieving high optical transmittance and electrical conductivity. Moreover, light trapping designs via patterning of the back thick metal electrode into different nanostructures, which can deliver a considerable efficiency improvement of photovoltaic devices, contribute by the plasmon-enhanced light-mattering interactions. Therefore, here the recent works of metal-based transparent electrodes and patterned back electrodes in photovoltaics are reviewed, which may push the future development of this exciting field.

Effect of Graphene-EC on Ag NW-Based Transparent Film Heaters: Optimizing the Stability and Heat Dispersion of Films

To optimize the performance of silver nanowire (Ag NW) film heaters and explore the effect of graphene on a film, we introduced poly(3,4-ethylenedioxythiophene):poly(4-styrenesulfonate) (PEDOT:PSS) and graphene modified with ethyl cellulose (graphene-EC) into the film. The high-quality and well-dispersed graphene-EC was synthesized from graphene obtained by electrochemical exfoliation as a precursor. The transparent film heaters were fabricated via spin-coating. With the assistance of graphene-EC, the stability of film heaters was greatly improved, and the conductivity was optimized by adjusting the Ag NW concentration. The film heaters exhibited a fast and accurate response to voltage, accompanied by excellent environmental endurance, and there was no significant performance degradation after being operated for a long period of time. These results indicate that graphene-EC plays a crucial role in optimizing film stability and heat dispersion in the film. The Ag NW/PEDOT:PSS-doped graphene-EC film heaters show a great potential in low-cost indium-tin-oxide-free flexible transparent electrodes, heating systems, and transparent film heaters.

Transparent and flexible Sb-doped SnO2 films with a nanoscale AgTi alloyed interlayer for heat generation and shielding applications

Transparent and flexible Sb-doped SnO₂ (ATO) films with a nanoscale AgTi alloyed interlayer were fabricated for use as plasma damage-free, indium-free, thermally stable electrodes for high performance heat generating films and shielding films in smart windows. The AgTi alloy-inserted ATO film on a PET substrate showed a low sheet resistance of 6.91 ohm per square and a high optical transmittance of 90.24% without thermal annealing or intentional substrate heating. Even after deformation using an outer bending radius of 4 mm, the ATO film with a AgTi interlayer showed a constant sheet resistance due to the mechanical robustness of the AgTi interlayer. Furthermore, the AgTi-inserted ATO film showed a constant resistance even after annealing at 500 °C, unlike the Ag-inserted ATO films. Furthermore, we demonstrated the feasibility of the AgTi-inserted ATO films as transparent heat generating films and shielding films for smart windows. The effective heat generation and shield performance of the ATO/Ag–Ti/ATO multilayer suggests that the multi-functional ATO/Ag–Ti/ATO films can be used to create energy-efficient smart windows for building energy management systems and automobiles.

Transparent and flexible ATO films with a nanoscale AgTi alloyed interlayer were fabricated for high performance heat generating and shielding films in smart windows.

Metal Nanowire-Coated Metal Woven Mesh for High-Performance Stretchable Transparent Electrodes

This work presents a new template-assisted fabrication method to obtain stretchable metal grids for high-performance stretchable transparent conducting electrodes (TCEs). Readily accessible metal woven mesh (MWM) is used as a template to make the fabrication process simple, cost-effective, reproducible, and potentially scalable by combining it with silver nanowire (AgNW) coating and elastomer filling processes. Stretchable TCEs are made with the AgNW-coated MWM and show remarkable optoelectronic performance with a sheet resistance of ∼3.2 Ω/sq and optical transmittance of >80%, large maximum stretchability of 40%, and electrical and mechanical robustness even under repeated stretching and bending deformations (1000 cycles). The device is demonstrated in a highly flexible touch screen panel that can operate well even in a bent state.

Transparent and Flexible Supercapacitors with Networked Electrodes

Transparent and flexible energy storage devices have received immense attention due to their suitability for innovative electronics and displays. However, it remains a great challenge to fabricate devices with high storage capacity and high degree of transmittance. This study describes a simple process for fabrication of supercapacitors with ≈75% of visible transparency and areal capacitance of ≈3 mF cm^-2 with high stability tested over 5000 cycles of charging and discharging. The electrodes consist of Au wire networks obtained by a simple crackle template method which are coated with MnO₂ nanostructures by electrodeposition process. Importantly, the membrane separator itself is employed as substrate to bring in the desired transparency and light weight while additionally exploiting its porous nature in enhancing the interaction of electrolyte with the active material from both sides of the substrate, thereby enhancing the storage capacity. The method opens up new ways for fabricating transparent devices.

A Consecutive Spray Printing Strategy to Construct and Integrate Diverse Supercapacitors on Various Substrates

The rapid development of printable electronic devices with flexible and wearable characteristics requires supercapacitor devices to be printable, light, thin, integrated macro- and micro-devices with flexibility. Herein, we developed a consecutive spray printing strategy to controllably construct and integrate diverse supercapacitors on various substrates. In such a strategy, all supercapacitor components are fully printable, and their thicknesses and shapes are well controlled. As a result, supercapacitors obtained by this strategy achieve diverse structures and shapes. In addition, different nanocarbon and pseudocapacitive materials are applicable for the fabrication of these diverse supercapacitors. Furthermore, the diverse supercapacitors can be readily constructed on various objects with planar, curved, or even rough surfaces (e.g., plastic film, glass, cloth, and paper). More importantly, the consecutive spray printing process can integrate several supercapacitors together in the perpendicular and parallel directions of one substrate by designing the structure of electrodes and separators. This enlightens the construction and integration of fully printable supercapacitors with diverse configurations to be compatible with fully printable electronics on various substrates.

All-Polymeric Flexible Transparent Heaters

All-polymeric flexible transparent heaters (THs) are demonstrated for the first time. Thin films of four poly(3,4-ethylenedioxythiophene) (PEDOT)-based materials embedding different dopants exhibit low sheet resistances, down to 57 Ω sq^-1 associated with good transparencies (>87%) and a haze lower than 1%. These transparent thin films show excellent heating properties, with high heating rates (up to 1.6 °C s^-1) and steady-state temperatures exceeding 100 °C when subjected to 12 V bias. Very high areal power densities were also measured, reaching almost 10 000 W m^-2. The temperature increase is finely fitted to a thermal model. It is further demonstrated that these new THs can be efficiently integrated for applications in thermochromic displays and visor deicers.

Microscopic Evaluation of Electrical and Thermal Conduction in Random Metal Wire Networks

Ideally, transparent heaters exhibit uniform temperature, fast response time, high achievable temperatures, low operating voltage, stability across a range of temperatures, and high optical transmittance. For metal network heaters, unlike for uniform thin-film heaters, all of these parameters are directly or indirectly related to the network geometry. In the past, at equilibrium, the temperature distributions within metal networks have primarily been studied using either a physical temperature probe or direct infrared (IR) thermography, but there are limits to the spatial resolution of these cameras and probes, and thus, only average regional temperatures have typically been measured. However, knowledge of local temperatures within the network with a very high spatial resolution is required for ensuring a safe and stable operation. Here, we examine the thermal properties of random metal network thin-film heaters fabricated from crack templates using high-resolution IR microscopy. Importantly, the heaters achieve predominantly uniform temperatures throughout the substrate despite the random crack network structure (e.g., unequal sized polygons created by metal wires), but the temperatures of the wires in the network are observed to be significantly higher than the substrate because of the significant thermal contact resistance at the interface between the metal and the substrate. Last, the electrical breakdown mechanisms within the network are examined through transient IR imaging. In addition to experimental measurements of temperatures, an analytical model of the thermal properties of the network is developed in terms of geometrical parameters and material properties, providing insights into key design rules for such transparent heaters. Beyond this work, the methods and the understanding developed here extend to other network-based heaters and conducting films, including those that are not transparent.

Asymmetric Pentagonal Metal Meshes for Flexible Transparent Electrodes and Heaters

Metal meshes have emerged as an important class of flexible transparent electrodes. We report on the characteristics of a new class of asymmetric meshes, tiled using a recently discovered family of pentagons. Micron-scale meshes were fabricated on flexible polyethylene terephthalate substrates via optical lithography, metal evaporation (Ti 10 nm, Pt 50 nm), and lift-off. Three different designs were assessed, each with the same tessellation pattern and line width (5 μm), but with different sizes of the fundamental pentagonal unit. Good mechanical stability was observed for both tensile strain and compressive strain. After 1000 bending cycles, devices subjected to tensile strain showed fractional resistance increases in the range of 8-17%, while devices subjected to compressive strain showed fractional resistance increases in the range of 0-7%. The performance of the pentagonal metal mesh devices as visible transparent heaters via Joule heating was also assessed. Rapid response times (∼15 s) at low bias voltage (≤5 V) and good thermal resistance characteristics (213-258 °C cm²/W) were found using measured thermal imaging data. Deicing of an ice-bearing glass coupon on top of the transparent heater was also successfully demonstrated.

Highly flexible and semi-transparent Ag–Cu alloy electrodes for high performance flexible thin film heaters

We investigated the properties of thermally evaporated Ag–Cu films for application as flexible and semi-transparent electrodes for semi-transparent flexible thin film heaters (TFHs) and heat shielding films (HSFs).

Investigating Polymer-Metal Interfaces by Grazing Incidence Small-Angle X-Ray Scattering from Gradients to Real-Time Studies

Tailoring the polymer-metal interface is crucial for advanced material design. Vacuum deposition methods for metal layer coating are widely used in industry and research. They allow for installing a variety of nanostructures, often making use of the selective interaction of the metal atoms with the underlying polymer thin film. The polymer thin film may eventually be nanostructured, too, in order to create a hierarchy in length scales. Grazing incidence X-ray scattering is an advanced method to characterize and investigate polymer-metal interfaces. Being non-destructive and yielding statistically relevant results, it allows for deducing the detailed polymer-metal interaction. We review the use of grazing incidence X-ray scattering to elucidate the polymer-metal interface, making use of the modern synchrotron radiation facilities, allowing for very local studies via in situ (so-called "stop-sputter") experiments as well as studies observing the nanostructured metal nanoparticle layer growth in real time.

Two-Dimensional SiO2/VO2 Photonic Crystals with Statically Visible and Dynamically Infrared Modulated for Smart Window Deployment

Two-dimensional (2D) photonic structures, widely used for generating photonic band gaps (PBG) in a variety of materials, are for the first time integrated with the temperature-dependent phase change of vanadium dioxide (VO₂). VO₂ possesses thermochromic properties, whose potential remains unrealized due to an undesirable yellow-brown color. Here, a SiO₂/VO₂ core/shell 2D photonic crystal is demonstrated to exhibit static visible light tunability and dynamic near-infrared (NIR) modulation. Three-dimensional (3D) finite difference time domain (FDTD) simulations predict that the transmittance can be tuned across the visible spectrum, while maintaining good solar regulation efficiency (ΔT_sol = 11.0%) and high solar transmittance (T_lum = 49.6%). Experiments show that the color changes of VO₂ films are accompanied by NIR modulation. This work presents a novel way to manipulate VO₂ photonic structures to modulate light transmission as a function of wavelength at different temperatures.

A deep look into the spray coating process in real-time-the crucial role of x-rays

Tailoring functional thin films and coating by rapid solvent-based processes is the basis for the fabrication of large scale high-end applications in nanotechnology. Due to solvent loss of the solution or dispersion inherent in the installation of functional thin films and multilayers the spraying and drying processes are strongly governed by non-equilibrium kinetics, often passing through transient states, until the final structure is installed. Therefore, the challenge is to observe the structural build-up during these coating processes in a spatially and time-resolved manner on multiple time and length scales, from the nanostructure to macroscopic length scales. During installation, the interaction of solid-fluid interfaces and between the different layers, the flow and evaporation themselves determine the structure of the coating. Advanced x-ray scattering methods open a powerful pathway for observing the involved processes in situ, from the spray to the coating, and allow for gaining deep insight in the nanostructuring processes. This review first provides an overview over these rapidly evolving methods, with main focus on functional coatings, organic photovoltaics and organic electronics. Secondly the role and decisive advantage of x-rays is outlined. Thirdly, focusing on spray deposition as a rapidly emerging method, recent advances in investigations of spray deposition of functional materials and devices via advanced x-ray scattering methods are presented.

Direct and contactless electrical control of temperature of paper and textile foldable substrates using electrospun metallic-web transparent electrodes

Multiple and complex functionalities are a demand nowadays for almost all materials, including common day-to-day materials such as paper, textiles, wood, etc. In the present report, the surface temperature control of different types of materials, including paper and textiles, was demonstrated by Joule heating of metallic-web transparent electrodes both by direct current and by RF induced eddy currents. Polymeric submicronic fiber webs were prepared by electrospinning, and metal sputtering was subsequently performed to transform them into flexible transparent electrodes. These electrodes were thermally attached to different substrates, including paper, textiles and glass. Using thermochromic inks, we demonstrated a high degree of control of the substrates' surface temperature by means of the Joule effect. Metallic fiber webs appear to be excellently suited for use as transparent electrodes for controlling the surface temperature of common materials, their highly flexible nature being a major advantage when dealing with rough, bendable substrates. This kind of result could not be achieved on bendable substrates with rough surfaces such as paper or textiles while employing classical transparent electrodes i.e. metal oxides. Moreover, contactless heating with induced currents is a premiere for transparent electrodes and opens up a score of new application fields.

High-Performance Flexible Transparent Electrode with an Embedded Metal Mesh Fabricated by Cost-Effective Solution Process

A new structure of flexible transparent electrodes is reported, featuring a metal mesh fully embedded and mechanically anchored in a flexible substrate, and a cost-effective solution-based fabrication strategy for this new transparent electrode. The embedded nature of the metal-mesh electrodes provides a series of advantages, including surface smoothness that is crucial for device fabrication, mechanical stability under high bending stress, strong adhesion to the substrate with excellent flexibility, and favorable resistance against moisture, oxygen, and chemicals. The novel fabrication process replaces vacuum-based metal deposition with an electrodeposition process and is potentially suitable for high-throughput, large-volume, and low-cost production. In particular, this strategy enables fabrication of a high-aspect-ratio (thickness to linewidth) metal mesh, substantially improving conductivity without considerably sacrificing transparency. Various prototype flexible transparent electrodes are demonstrated with transmittance higher than 90% and sheet resistance below 1 ohm sq(-1) , as well as extremely high figures of merit up to 1.5 × 10(4) , which are among the highest reported values in recent studies. Finally using our embedded metal-mesh electrode, a flexible transparent thin-film heater is demonstrated with a low power density requirement, rapid response time, and a low operating voltage.

Visibly Transparent Heaters

Heater plates or sheets that are visibly transparent have many interesting applications in optoelectronic devices such as displays, as well as in defrosting, defogging, gas sensing and point-of-care disposable devices. In recent years, there have been many advances in this area with the advent of next generation transparent conducting electrodes (TCE) based on a wide range of materials such as oxide nanoparticles, CNTs, graphene, metal nanowires, metal meshes and their hybrids. The challenge has been to obtain uniform and stable temperature distribution over large areas, fast heating and cooling rates at low enough input power yet not sacrificing the visible transmittance. This review provides topical coverage of this important research field paying due attention to all the issues mentioned above.

Composites of Graphene Nanoribbon Stacks and Epoxy for Joule Heating and Deicing of Surfaces

A conductive composite of graphene nanoribbon (GNR) stacks and epoxy is fabricated. The epoxy is filled with the GNR stacks, which serve as a conductive additive. The GNR stacks are on average 30 nm thick, 250 nm wide, and 30 μm long. The GNR-filled epoxy composite exhibits a conductivity >100 S/m at 5 wt % GNR content. This permits application of the GNR-epoxy composite for deicing of surfaces through Joule (voltage-induced) heating generated by the voltage across the composite. A power density of 0.5 W/cm(2) was delivered to remove ∼1 cm-thick (14 g) monolith of ice from a static helicopter rotor blade surface in a -20 °C environment.

Unstable crack propagation in LAPONITE® gels: selection of a sinusoidal mode in an electric field

We report observation of wavy cracks and naturally patterned fracture surfaces in drying LAPONITE® paste.

Random nanocrack, assisted metal nanowire-bundled network fabrication for a highly flexible and transparent conductor

Bundled metal nanowire network transparent conductor with enhanced mechanical characteristics was fabricated from random crack patterns.

Highly transparent silver nanowire–polyimide electrode as a snow-cleaning device

A transparent colorless AgNW–PI electrode exhibited excellent thermal stability and adhesion property for a snow-cleaning application.

Fabrication of Oxidation-Resistant Metal Wire Network-Based Transparent Electrodes by a Spray-Roll Coating Process

Roll and spray coating methods have been employed for the fabrication of highly oxidation resistant transparent and conducting electrodes (TCEs) by a simple solution process using crackle lithography technique. We have spray-coated a crackle paint-based precursor to produce highly interconnected crackle network on PET roll mounted on a roll coater with web speed of 0.6 m/min. Ag TCE with a transmittance of 78% and sheet resistance of ∼20 Ω/□ was derived by spraying Ag precursor ink over the crackle template followed by lift-off and annealing under ambient conditions. The Ag wire mesh was stable toward bending and sonication tests but prone to oxidation in air. When electrolessly coated with Pd, its robustness toward harsh oxidation conditions was enhanced. A low-cost transparent electrode has also been realized by using only small amounts of Ag as seed layer and growing Cu wire mesh by electroless method. Thus, made Ag/Cu meshes are found to be highly stable for more than a year even under ambient atmosphere.

Aligned carbon nanotube film enables thermally induced state transformations in layered polymeric materials

The energy losses and geometric constraints associated with conventional curing techniques of polymeric systems motivate the study of a highly scalable out-of-oven curing method using a nanostructured resistive heater comprised of aligned carbon nanotubes (A-CNT). The experimental results indicate that, when compared to conventional oven based techniques, the use of an "out-of-oven" A-CNT integrated heater leads to orders of magnitude reductions in the energy required to process polymeric layered structures such as composites. Integration of this technology into structural systems enables the in situ curing of large-scale polymeric systems at high efficiencies, while adding sensing and control capabilities.