A three-dimensional metal grid mesh as a practical alternative to ITO

Flexible Transparent Conductive Electrodes: Unveiling Growth Mechanisms, Material Dimensions, Fabrication Methods, and Design Strategies

Flexible transparent conductive electrodes (FTCEs) constitute an indispensable component in state-of-the-art electronic devices, such as wearable flexible sensors, flexible displays, artificial skin, and biomedical devices, etc. This review paper offers a comprehensive overview of the fabrication techniques, growth modes, material dimensions, design, and their impacts on FTCEs fabrication. The growth modes, such as the "Stranski-Krastanov growth," "Frank-van der Merwe growth," and "Volmer-Weber growth" modes provide flexibility in fabricating FTCEs. Application of different materials including 0D, 1D, 2D, polymer composites, conductive oxides, and hybrid materials in FTCE fabrication, emphasizing their suitability in flexible devices are discussed. This review also delves into the design strategies of FTCEs, including microgrids, nanotroughs, nanomesh, nanowires network, and "kirigami"-inspired patterns, etc. The pros and cons associated with these materials and designs are also addressed appropriately. Considerations such as trade-offs between electrical conductivity and optical transparency or "figure of merit (FoM)," "strain engineering," "work function," and "haze" are also discussed briefly. Finally, this review outlines the challenges and opportunities in the current and future development of FTCEs for flexible electronics, including the improved trade-offs between optoelectronic parameters, novel materials development, mechanical stability, reproducibility, scalability, and durability enhancement, safety, biocompatibility, etc.

Comparative Study on Preparation Methods for Transparent Conductive Films Based on Silver Nanowires

Silver nanowires, which have high optoelectronic properties, have the potential to supersede indium tin oxide in the field of electrocatalysis, stretchable electronic, and solar cells. Herein, four mainstream experimental methods, including Mayer-rod coating, spin coating, spray coating, and vacuum filtration methods, are employed to fabricate transparent conductive films based on the same silver nanowires to clarify the significance of preparation methods on the performance of the films. The surface morphology, conductive property, uniformity, and flexible stability of these four Ag NW-based films, are analyzed and compared to explore the advantages of these methods. The transparent conductive films produced by the vacuum filtration method have the most outstanding performance in terms of surface roughness and uniformity, benefitting from the stronger welding of NW-NW junctions after the press procedure. However, limited by the size of the membrane and the vacuum degree of the equipment, the small-size Ag films used in precious devices are appropriate to obtain through this method. Similarly, the spin coating method is suited to prepare Ag NWs films with small sizes, which shows excellent stability after the bending test. In comparison, much larger-size films could be obtained through Mayer-rod coating and spray coating methods. The pull-down speed and force among the Mayer-rod coating process, as well as the spray distance and traveling speed among the spray coating process, are essential to the uniformity of Ag NW films. After being treated with NaBH₄ and polymethyl methacrylate (PMMA), the obtained Ag NW/PMMA films show great potential in the field of film defogging due to the Joule heating effect. Taken together, based on the advantages of each preparation method, the Ag NW-based films with desired size and performances are easier to prepare, meeting the requirements of different application fields.

Cohesively Enhancing the Conductance, Mechanical Robustness, and Environmental Stability of Random Metallic Mesh Electrodes via Hot-Pressing-Induced In-Plane Configuration

Flexible transparent conductive electrode (FTCE) is highly desirable due to the fast-growing flexible optoelectronic devices. Several promising FTCEs based on metal material have been developed to replace conventional indium tin oxide (ITO). The random metal mesh is considered to be one of the competitive candidates. However, obtaining feasible random metal mesh with low sheet resistance, high transparency, good mechanical durability, and strong environmental stability is still a great challenge. Here, a random metal mesh-based FTCE with an in-plane structure, achieved by a facile hot-pressing process, is demonstrated. The hot-pressing process enables the fabrication of highly conductive FTCE with improved mechanical robustness and environmental stability. The in-plane FTCE shows a low sheet resistance of 1.63 Ω·sq^-1 with an 80.6% transmittance, low relative resistance increase (RRI) of 7.9% after 240 h 85 °C/85% RH test, and low RRI of 8.0% after 10⁵ cycles of bending test. Besides, various applications of the in-plane FTCE were demonstrated, including the flexible heater, flexible touch screen, and flexible electroluminescence. We anticipate that these results will spark interest in in-plane random metal mesh electrodes and enable the application of random metal mesh in flexible optoelectronic devices.

Templateless, Plating-Free Fabrication of Flexible Transparent Electrodes with Embedded Silver Mesh by Electric-Field-Driven Microscale 3D Printing and Hybrid Hot Embossing

Flexible transparent electrodes (FTEs) with an embedded metal mesh are considered a promising alternative to traditional indium tin oxide (ITO) due to their excellent photoelectric performance, surface roughness, and mechanical and environmental stability. However, great challenges remain for achieving simple, cost-effective, and environmentally friendly manufacturing of high-performance FTEs with embedded metal mesh. Herein, a maskless, templateless, and plating-free fabrication technique is proposed for FTEs with embedded silver mesh by combining an electric-field-driven (EFD) microscale 3D printing technique and a newly developed hybrid hot-embossing process. The final fabricated FTE exhibits superior optoelectronic properties with a transmittance of 85.79%, a sheet resistance of 0.75 Ω sq^-1 , a smooth surface of silver mesh (R_a  ≈ 18.8 nm) without any polishing treatment, and remarkable mechanical stability and environmental adaptability with a negligible increase in sheet resistance under diverse cyclic tests and harsh working conditions (1000 bending cycles, 80 adhesion tests, 120 scratch tests, 100 min ultrasonic test, and 72 h chemical attack). The practical viability of this FTE is successfully demonstrated with a flexible transparent heater applied to deicing. The technique proposed offers a promising fabrication strategy with a cost-effective and environmentally friendly process for high-performance FTE.

Highly transparent and conductive electrodes enabled by scalable printing-and-sintering of silver nanowires

Silver nanowires (Ag NWs) have good promised for flexible and transparent electronics. However, It remains an open question on how to achieve large-scale printing of Ag NWs with high optical transparency, electrical conductivity, and mechanical durability for practical applications, though extensive research has been conducted for more than a decade. In this work, we propose a possible solution that integrates screen printing of Ag NWs with flash-light sintering (FLS). We demonstrate that the use of low-concentration, screen-printable Ag NW ink enables large-area and high-resolution patterning of Ag NWs. A critical advantage comes from the FLS process that allows low-temperature processing, short operational time, and high output rate-characteristics that fit the scalable manufacturing. Importantly, we show that the resultant Ag NW patterns feature low sheet resistance (1.1-9.2 Ohm sq^-1), high transparency (75.2-92.6%), and thus a remarkable figure of merit comparable to state of the art. These outstanding properties of Ag NW patterns, together with the scalable fabrication method we propose, would facilitate many Ag NW-based applications, such as transparent heaters, stretchable displays, and wearable devices; here, we demonstrate the novel design of flexible and transparent radio frequency 5G antennas.

Recent Progress in Simple and Cost-Effective Top-Down Lithography for ≈10 nm Scale Nanopatterns: From Edge Lithography to Secondary Sputtering Lithography

The development of a simple and cost-effective method for fabricating ≈10 nm scale nanopatterns over large areas is an important issue, owing to the performance enhancement such patterning brings to various applications including sensors, semiconductors, and flexible transparent electrodes. Although nanoimprinting, extreme ultraviolet, electron beams, and scanning probe litho-graphy are candidates for developing such nanopatterns, they are limited to complicated procedures with low throughput and high startup cost, which are difficult to use in various academic and industry fields. Recently, several easy and cost-effective lithographic approaches have been reported to produce ≈10 nm scale patterns without defects over large areas. This includes a method of reducing the size using the narrow edge of a pattern, which has been attracting attention for the past several decades. More recently, secondary sputtering lithography using an ion-bombardment technique was reported as a new method to create high-resolution and high-aspect-ratio structures. Recent progress in simple and cost-effective top-down lithography for ≈10 nm scale nanopatterns via edge and secondary sputtering techniques is reviewed. The principles, technical advances, and applications are demonstrated. Finally, the future direction of edge and secondary sputtering lithography research toward issues to be resolved to broaden applications is discussed.

Transparent Flexible Nanoline Field-Effect Transistor Array with High Integration in a Large Area

Transparent flexible transistor array requests large-area fabrication, high integration, high manufacturing throughput, inexpensive process, uniformity in transistor performance, and reproducibility. This study suggests a facile and reliable approach to meet the requirements. We use the Al-coated polymer nanofiber patterns obtained by electrohydrodynamic (EHD) printing as a photomask. We use the lithography and deposition to produce highly aligned nanolines (NLs) of metals, insulators, and semiconductors on large substrates. With these NLs, we demonstrate a highly integrated NL field-effect transistor (NL-FET) array (10⁵/(4 × 4 in²), 254 pixel-per-inch) made of pentacene and indium zinc oxide semiconductor NLs. In addition, we demonstrate a NL complementary inverter (NL-CI) circuit consisting of pentacene and fullerene NLs. The NL-FET array shows high transparency (∼90%), flexibility (stable at 2.5 mm bending radius), uniformity (∼90%), and high performances (mobility = 0.52 cm²/(V s), on-off ratio = 7.0 × 10⁶). The NL-CI circuit also shows high transparency, flexibility, and typical switching characteristic with a gain of 21. The reliable large-scale fabrication of the various NLs proposed in this study is expected to be applied for manufacturing transparent flexible nanoelectronic devices.

The synthesis of silver nanowires with tunable diameters using halide ions for flexible transparent conductive films

The diameter of Ag nanowires could be tuned in the range of 19 to 35 nm with the cooperation of Cl⁻ and Br⁻ ions.

Fabrication of High-Performance Silver Mesh for Transparent Glass Heaters via Electric-Field-Driven Microscale 3D Printing and UV-Assisted Microtransfer

Great challenges remain concerning the cost-effective manufacture of high-performance metal meshes for transparent glass heaters (TGHs). Here, a high-performance silver mesh fabrication technique is proposed for TGHs using electric-field-driven microscale 3D printing and a UV-assisted microtransfer process. The results show a more optimal trade-off in sheet resistance (R_s = 0.21 Ω sq^-1 ) and transmittance (T = 93.9%) than for indium tin oxide (ITO) and ITO substitutes. The fabricated representative TGH also exhibits homogeneous and stable heating performance, remarkable environmental adaptability (constant R_s for 90 days), superior mechanical robustness (R_s increase of only 0.04 in harsh conditions-sonication at 100 °C), and strong adhesion force with a negligible increase in R_s (2-12%) after 100 peeling tests. The practical viability of this TGH is successfully demonstrated with a deicing test (ice cube: 21 cm³ , melting time: 78 s, voltage and glass thickness: 4 V, 5 mm). All of these advantages of the TGHs are attributed to the successful fabrication of silver meshes with high resolution and high aspect ratio on the glass substrate using the thick film silver paste. The proposed technique is a promising new tool for the inexpensive fabrication of high-performance TGHs.

Highly Transparent, Flexible Conductors and Heaters Based on Metal Nanomesh Structures Manufactured Using an All-Water-Based Solution Process

Metal mesh is a promising material for flexible transparent conducting electrodes due to its outstanding physical and electrical properties. The excellent control of the sheet resistance and transmittance provided by the metal mesh electrodes is a great advantage for microelectronic applications. Thus, over the past decade, many studies have been performed in order to realize high-performance metal mesh; however, the lack of cost-effective fabrication processes and the weak adhesion between the metal mesh and substrate have hindered its widespread adoption for flexible optoelectronic applications. In this study, a new approach for fabricating robust silver mesh without using hazardous organic solvents is achieved by combining colloidal deposition and silver enhancement steps. The adhesion of the metal mesh was greatly improved by introducing an intermediate adhesion layer. Various patterns relevant to optoelectronic applications were fabricated with a minimum feature size of 700 nm, resulting in high optical transmittance of 97.7% and also high conductivity (71.6 Ω sq^-1) of the metal mesh. In addition, we demonstrated an effective transparent heater using the silver mesh with excellent exothermic behavior, which heated up to 245 °C with 7 V applied voltage.

Highly Transparent and Flexible All-Solid-State Supercapacitors Based on Ultralong Silver Nanowire Conductive Networks

Ultralong silver nanowires (Ag NWs) are preferred for enabling transparent conductive networks with low sheet resistance, high transparency, and excellent mechanical flexibility, which offer great merits in achieving high-performance and flexible energy storage devices. Herein, a new type of polyol process was proposed for the synthesis of ultralong Ag NWs. Uniform Ag NWs with the average length of 75 μm were obtained. Transparent conductive films (TCFs) based on the as-prepared Ag NWs exhibited low sheet resistance of 15.2 Ω/sq at 84% transmittance with a negligible change in sheet resistance after bending. Flexible all-solid-state supercapacitors based on the resulting Ag NW TCFs showed high transparency (>50%), good mechanical flexibility, and high cyclic stability with only slight areal capacitance decays after 100 times of bending (∼25%) and 5000 charge-discharge cycles (∼15%). The results manifest great potentials of the resulting TCFs based on ultralong Ag NWs for flexible and wearable energy-storage applications.

A High Aspect Ratio Serpentine Structure for Use As a Strain-Insensitive, Stretchable Transparent Conductor

The development of strain-insensitive stretchable transparent conductors (TCs) is essential for manufacturing stretchable electronics. Despite recent progress, achieving a high optoelectronic performance under applied strain of 50% continues to present a significant challenge in this research field. Herein, an ultratall and ultrathin high aspect ratio serpentine metal structure is described that exhibits a remarkable stretching ability (the resistance remains constant under applied strain of 100%) and simultaneously provides an excellent transparent conducting performance (with a sheet resistance of 7.6 Ω ^-1 and a transmittance of 90.5%). It is demonstrated that the highly stretchable transparent conducting properties can be attributed to the high aspect ratio feature. A high aspect ratio (aspect ratio of 17-367) structure permits facile deformation of the serpentine structure with in-plane motion, leading to a high stretching ability. In addition, this structural feature avoids the classic tradeoff between optical transmittance and electrical conductance, providing a high electrical conductance without decreasing the optical transmittance. The practical utility of these devices is tested by using these TCs as stretchable interconnectors among LEDs or in wearable VOC gas sensors.

Fabrication of Flexible Transparent Electrode with Enhanced Conductivity from Hierarchical Metal Grids

Flexible transparent conductive electrodes (FTCEs) are essential components for numerous optoelectronic devices. In this work, we have fabricated the hierarchical metal grids (HMG) FTCEs by a facile and low-cost, near-field photolithography strategy. Compared to normal metal grids (MG), the HMG structure can provide distinctly increased conductivity of the electrode yet without obvious reduction of the optical transmittance. This HMG sample possesses excellent optoelectronic performance and high mechanical flexibility, making it a promising component for practical applications.

Self-Heating-Induced Deterioration of Electromechanical Performance in Polymer-Supported Metal Films for Flexible Electronics

The retention of electrical performance under the combined conditions of mechanical strain and an electrical current is essential for flexible electronics. Here, we report that even below the critical current density required for electromigration, the electrical current can significantly deteriorate the electromechanical performance of metal film/polymer substrate systems. This leads to a loss of stretchability, and this effect becomes more severe with increasing strain as well as increasing current. The local increase of electrical resistance in the metal film caused by damage, such as localized deformations, cracks, etc., locally raises the temperature of the test sample via Joule heating. This weakens the deformation resistance of the polymer substrate, accelerating the necking instability, and consequently leading to a rapid loss of electrical conductivity with strain. To minimize such a current-induced deterioration of the polymer-supported metal films, we develop and demonstrate the feasibility of two methods that enhance the deformation resistance of the polymer substrate at elevated temperatures: increasing the thickness of the polymer substrate, and utilizing a polymer substrate with a high glass transition temperature.

Flexible Transparent Conductive Films with High Performance and Reliability Using Hybrid Structures of Continuous Metal Nanofiber Networks for Flexible Optoelectronics

We report an Ag nanofiber-embedded glass-fabric reinforced hybrimer (AgNF-GFRHybrimer) composite film as a reliable and high-performance flexible transparent conducting film. The continuous AgNF network provides superior optoelectronic properties of the composite film by minimizing transmission loss and junction resistance. In addition, the excellent thermal/chemical stability and mechanical durability of the GFRHybrimer matrix provides enhanced mechanical durability and reliability of the final AgNF-GFRHybrimer composite film. To demonstrate the availability of our AgNF-GFRHybrimer composite as a transparent conducting film, we fabricated a flexible organic light-emitting diode (OLED) device on the AgNF-GFRHybrimer film; the OLED showed stable operation during a flexing.

Fabrication of three-dimensional hybrid nanostructure-embedded ITO and its application as a transparent electrode for high-efficiency solution processable organic photovoltaic devices

Well-aligned, high-resolution (10 nm), three-dimensional (3D) hybrid nanostructures consisting of patterned cylinders and Au islands were fabricated on ITO substrates using an ion bombardment process and a tilted deposition process. The fabricated 3D hybrid nanostructure-embedded ITO maintained its excellent electrical and optical properties after applying a surface-structuring process. The solution processable organic photovoltaic device (SP-OPV) employing a 3D hybrid nanostructure-embedded ITO as the anode displayed a 10% enhancement in the photovoltaic performance compared to the photovoltaic device prepared using a flat ITO electrode, due to the improved charge collection (extraction and transport) efficiency as well as light absorbance by the photo-active layer.