Ultrastretchable Conductive Elastomers with a Low Percolation Threshold for Printed Soft Electronics

Phase-separated porous nanocomposite with ultralow percolation threshold for wireless bioelectronics

Realizing the full potential of stretchable bioelectronics in wearables, biomedical implants and soft robotics necessitates conductive elastic composites that are intrinsically soft, highly conductive and strain resilient. However, existing composites usually compromise electrical durability and performance due to disrupted conductive paths under strain and rely heavily on a high content of conductive filler. Here we present an in situ phase-separation method that facilitates microscale silver nanowire assembly and creates self-organized percolation networks on pore surfaces. The resultant nanocomposites are highly conductive, strain insensitive and fatigue tolerant, while minimizing filler usage. Their resilience is rooted in multiscale porous polymer matrices that dissipate stress and rigid conductive fillers adapting to strain-induced geometry changes. Notably, the presence of porous microstructures reduces the percolation threshold (Vc = 0.00062) by 48-fold and suppresses electrical degradation even under strains exceeding 600%. Theoretical calculations yield results that are quantitatively consistent with experimental findings. By pairing these nanocomposites with near-field communication technologies, we have demonstrated stretchable wireless power and data transmission solutions that are ideal for both skin-interfaced and implanted bioelectronics. The systems enable battery-free wireless powering and sensing of a range of sweat biomarkers-with less than 10% performance variation even at 50% strain. Ultimately, our strategy offers expansive material options for diverse applications.

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.

Electrically Conducting Elastomeric Fibers with High Stretchability and Stability

Stretchable conducting materials are appealing for the design of unobtrusive wearable electronic devices. Conjugated polymers with oligoethylene glycol side chains are excellent candidate materials owing to their low elastic modulus and good compatibility with polar stretchable polymers. Here, electrically conducting elastomeric blend fibers with high stretchability, wet spun from a blend of a doped polar polythiophene with tetraethylene glycol side chains and a polyurethane are reported. The wet-spinning process is versatile, reproducible, scalable, and produces continuous filaments with a diameter ranging from 30 to 70 µm. The fibers are stretchable up to 480% even after chemical doping with iron(III) p-toluenesulfonate hexahydrate and exhibit an electrical conductivity of up to 7.4 S cm^-1 , which represents a record combination of properties for conjugated polymer-based fibers. The fibers remain conductive during elongation until fiber fracture and display excellent long-term stability at ambient conditions. Cyclic stretching up to 50% strain for at least 400 strain cycles reveals that the doped fibers exhibit high cyclic stability and retain their electrical conductivity. Finally, a directional strain sensing device, which makes use of the linear increase in resistance of the fibers up to 120% strain is demonstrated.

Conductive Polymer Nanocomposites for Stretchable Electronics: Material Selection, Design, and Applications

Stretchable electronics that can elongate elastically as well as flex are crucial to a wide range of emerging technologies, such as wearable medical devices, electronic skin, and soft robotics. Critical to stretchable electronics is their ability to withstand large mechanical strain without failure while retaining their electrical conduction properties, a feat significantly beyond traditional metals and silicon-based semiconductors. Herein, we present a review of the recent advances in stretchable conductive polymer nanocomposites with exceptional stretchability and electrical properties, which have the potential to transform a wide range of applications, including wearable sensors for biophysical signals, stretchable conductors and electrodes, and deformable energy-harvesting and -storage devices. Critical to achieving these stretching properties are the judicious selection and hybridization of nanomaterials, novel microstructure designs, and facile fabrication processes, which are the focus of this Review. To highlight the potentials of conductive nanocomposites, a summary of some recent important applications is presented, including COVID-19 remote monitoring, connected health, electronic skin for augmented intelligence, and soft robotics. Finally, perspectives on future challenges and new research opportunities are also presented and discussed.

Nonequilibrium Structure Diagram of Pendular Suspensions under Large-Amplitude Oscillatory Shear

For pendular suspensions with particles in contact with immiscible secondary liquid bridges, the shear field significantly influences particle aggregates and networks. In this work, we study the structure of the pendular network and how the structure changes under large-amplitude-oscillatory shear. Using rheology and optical microscopy, we found unique network destruction followed by reconstruction with increasing strain. Two processes show different shear-field dependencies, strain-rate dependency for destruction and strain dependency for reconstruction. A nonequilibrium state diagram is constructed to show the phase behavior, where the critical particle concentration of sol-gel transition is dependent on the shear history and may depend on shear strain nonmonotonically. Two different mechanisms, shear-induced network breakdown at low strain and shear-induced agglomeration at high strain, are suggested to describe the nonmonotonic critical concentration under the upward strain sweep quantitatively.

Uniform conductivity in stretchable silicones via multiphase inclusions

Many soft robotic components require highly stretchable, electrically conductive materials for proper operation. Often these conductive materials are used as sensors or as heaters for thermally responsive materials. However, there is a scarcity of stretchable materials that can withstand the high strains typically experienced by soft robots, while maintaining the electrical properties necessary for Joule heating (e.g., uniform conductivity). In this work, we present a silicone composite containing both liquid and solid inclusions that can maintain a uniform conductivity while experiencing 200% linear strains. This composite can be cast in thin sheets enabling it to be wrapped around thermally responsive soft materials that increase their volume or stretchability when heated. We show how this material opens up possibilities for electrically controllable shape changing soft robotic actuators, as well as all-silicone actuation systems powered only by electrical stimulus. Additionally, we show that this stretchable composite can be used as an electrode material in other applications, including a strain sensor with a linear response up to 200% strain and near-zero signal noise.

Advances in Materials for Soft Stretchable Conductors and Their Behavior under Mechanical Deformation

Soft stretchable sensors rely on polymers that not only withstand large deformations while retaining functionality but also allow for ease of application to couple with the body to capture subtle physiological signals. They have been applied towards motion detection and healthcare monitoring and can be integrated into multifunctional sensing platforms for enhanced human machine interface. Most advances in sensor development, however, have been aimed towards active materials where nearly all approaches rely on a silicone-based substrate for mechanical stability and stretchability. While silicone use has been advantageous in academic settings, conventional silicones cannot offer self-healing capability and can suffer from manufacturing limitations. This review aims to cover recent advances made in polymer materials for soft stretchable conductors. New developments in substrate materials that are compliant and stretchable but also contain self-healing properties and self-adhesive capabilities are desirable for the mechanical improvement of stretchable electronics. We focus on materials for stretchable conductors and explore how mechanical deformation impacts their performance, summarizing active and substrate materials, sensor performance criteria, and applications.

Three-Dimensional Hierarchical Wrinkles on Polymer Films: From Chaotic to Ordered Antimicrobial Topographies

Microbial contamination of polymer surfaces has become a significant challenge in domestic, industrial, and biomedical applications. Recent progress in our understanding of how topographical features of different length scales can be used to effectively and selectively control the attachment and proliferation of different cell types has provided an alternative strategy for imparting antibacterial activity to these surfaces. Among the well-recognized engineered models of antibacterial surface topographies, self-organized wrinkles have shown particular promise with respect to their antimicrobial characteristics. Here, we critically review the mechanisms by which wrinkles form on the surface of different types of polymer material and how they interact with various biomolecules and cell types. We also discuss the feasibility of using this antimicrobial strategy in real-life biomedical applications.