Screen-Printed Corrosion-Resistant and Long-Term Stable Stretchable Electronics Based on AgAu Microflake Conductors

High-throughput production methods such as screen printing can bring stretchable electronics out of the lab into the market. Most stretchable conductor inks for screen printing are based on silver nanoparticles or flakes due to their favorable performance-to-cost ratio, but silver is prone to tarnishing and corrosion, thereby limiting the stability of such conductors. Here, we report on a cost-efficient and scalable approach to resolve this issue by developing screen printable inks based on silver flakes chemically coated by a thin layer of gold. The printed stretchable AgAu conductors reach a conductivity of 8500 S cm^-1, remain conductive up to 250% strain, show excellent corrosion and tarnishing stability, and are used to demonstrate wearable LED and NFC circuits. The reported approach is attractive for smart clothing, as the long-term functionality of such devices is expected in a variety of environments.

A Novel Preparation Method of Electrically Conductive Adhesives by Powder Spraying Process

In a conventional electrically conductive adhesive (ECA) preparation process, typical ECAs are made by adding an appropriate amount of electrically conductive fillers, such as silver, into a polymer matrix, such as epoxy resin, to form a uniformly dispersed mixture by mixing and stirring operations. However, during the preparation process, secondary pollution and mass loss are caused by the vigorous mixture process. At the same time, the stirring operation introduces many small and stable bubbles, which affect the electrical conductivity of the ECAs. In light of these problems with the conventional preparation of ECAs, we developed a novel ECA preparation method that employs a powder spraying process: silver flakes are sprayed into the epoxy resin with a certain mass fraction to form formulated pastes. The as-prepared ECAs exhibited excellent properties compared with those prepared by the conventional process. This proves that the powder spraying process is feasible and superior to the conventional process.

Matrix-Independent Highly Conductive Composites for Electrodes and Interconnects in Stretchable Electronics

Electrically conductive composites (ECCs) hold great promise in stretchable electronics because of their printability, facile preparation, elasticity, and possibility for large-area fabrication. A high conductivity at steady state and during mechanical deformation is a critical property for ECCs, and extensive efforts have been made to improve the conductivity. However, most of those approaches are exclusively functional to a specific polymer matrix, restricting their capability to meet other requirements, such as mechanical, adhesive, and thermomechanical properties. Here, we report a generic approach to prepare ECCs with conductivity close to that of bulk metals and maintain their conductivity during stretching. This approach iodizes the surfactants on the commercial silver flakes, and subsequent photo exposure converts these silver iodide nanoparticles to silver nanoparticles. The ECCs based on silver nanoparticle-covered silver flakes exhibit high conductivity because of the removal of insulating surfactants as well as the enhanced contact between flakes. The treatment of silver flakes is independent of the polymer matrix and provides the flexibility in matrix selection. In the development of stretchable interconnects, ECCs can be prepared with the same polymer as the substrate to ensure strong adhesion between interconnects and the substrate. For the fabrication of on-skin electrodes, a polymer matrix of low modulus can be selected to enhance conformal contact with the skin for reduced impedance.

In Situ Generation of Photosensitive Silver Halide for Improving the Conductivity of Electrically Conductive Adhesives

Electrically conductive adhesives (ECAs) can be regarded as one of the most promising materials to replace tin/lead solder. However, relatively low conductivity seriously restricts their applications. In the present study, we develop an effective method to decrease the bulk electrical resistivity of ECAs. KI or KBr is added to replace the lubricant and silver oxide layers on silver flakes and to form photosensitive silver halide. After exposure to sunlight, silver halide can photodecompose into silver nanoparticles that will sinter and form metallic bonding between/among flakes during the curing process of ECAs, which would remarkably reduce the resistivity. The modified micro silver flakes play a crucial role in decreasing the electrical resistivity of the corresponding ECAs, exhibiting the lowest resistivity of 7.6 × 10^-5 Ω·cm for 70 wt % loaded ECAs. The obtained ECAs can have wide applications in the electronics industry, where high conductance is required.