Recent progress in strain-engineered elastic platforms for stretchable thin-film devices

Photo-crosslinkable organic materials for flexible and stretchable electronics

As technology advances to enhance human perceptual experiences of the surrounding environment, significant research on stretchable electronics is actively progressing, spanning from the synthesis of materials to their applications in fully integrated devices. A critical challenge lies in developing materials that can maintain their electrical properties under substantial stretching. Photo-crosslinkable organic materials have emerged as a promising solution due to their ability to be precisely modified with light to achieve desired properties, such as enhanced durability, stable conductivity, and micropatterning. This review examines recent research on photo-crosslinkable organic materials, focusing on their components and integration within stretchable electronic devices. We explore the essential characteristics required for each device component (insulators, semiconductors, and conductors) and explain how photo-crosslinking technology addresses these needs through its principles and implementation. Additionally, we discuss the integration and utilization of these components in real-world applications, including physical sensors, organic field-effect transistors (OFETs), and organic solar cells (OSCs). Finally, we offer a concise perspective on the future directions and potential challenges in ongoing research on photo-crosslinkable organic materials.

Regio-Selective Mechanical Enhancement of Polymer-Grafted Nanoparticle Composites via Light-Mediated Crosslinking

Polymer-brush-grafted nanoparticles (PGNPs) that can be covalently crosslinked post-processing enable the fabrication of mechanically robust and chemically stable polymer nanocomposites with high inorganic filler content. Modifying PGNP brushes to append UV-activated crosslinkers along the polymer chains would permit a modular crosslinking strategy applicable to a diverse range of nanocomposite compositions. Further, light-activated crosslinking reactions enable spatial control of crosslink density to program intentionally inhomogeneous mechanical responses. Here, a method of synthesizing composites using UV-crosslinkable brush-coated nanoparticles (referred to as UV-XNPs) is introduced that can be applied to various monomer compositions by incorporating photoinitiators into the polymer brushes. UV crosslinking of processed UV-XNP structures can increase their tensile modulus up to 15-fold without any noticeable alteration to their appearance or shape. By using photomasks to alter UV intensity across a sample, intentionally designed inhomogeneities in crosslink density result in predetermined anisotropic shape changes under strain. This unique capability of UV-XNP materials is applied to stiffness-patterned flexible electronic substrates that prevent the delamination of rigid components under deformation. The potential of UV-XNPs as functional, soft device components is further demonstrated by wearable devices that can be modified post-fabrication to customize their performance, permitting the ability to add functionality to existing device architectures.

A Printed Microscopic Universal Gradient Interface for Super Stretchable Strain-Insensitive Bioelectronics

Stretchable electronics capable of conforming to nonplanar and dynamic human body surfaces are central for creating implantable and on-skin devices for high-fidelity monitoring of diverse physiological signals. While various strategies have been developed to produce stretchable devices, the signals collected from such devices are often highly sensitive to local strain, resulting in inevitable convolution with surface strain-induced motion artifacts that are difficult to distinguish from intrinsic physiological signals. Here all-printed super stretchable strain-insensitive bioelectronics using a unique universal gradient interface (UGI) are reported to bridge the gap between soft biomaterials and stiff electronic materials. Leveraging a versatile aerosol-based multi-materials printing technique that allows precise spatial control over the local stiffnesses with submicron resolution, the UGI enables strain-insensitive electronic devices with negligible resistivity changes under a 180% uniaxial stretch ratio. Various stretchable devices are directly printed on the UGI for on-skin health monitoring with high signal quality and near-perfect immunity to motion artifacts, including semiconductor-based photodetectors for sensing blood oxygen saturation levels and metal-based temperature sensors. The concept in this work will significantly simplify the fabrication and accelerate the development of a broad range of wearable and implantable bioelectronics for real-time health monitoring and personalized therapeutics.

A universal packaging substrate for mechanically stable assembly of stretchable electronics

Stretchable electronics commonly assemble multiple material modules with varied bulk moduli and surface chemistry on one packaging substrate. Preventing the strain-induced delamination between the module and the substrate has been a critical challenge. Here we develop a packaging substrate that delivers mechanically stable module/substrate interfaces for a broad range of stiff and stretchable modules with varied surface chemistries. The key design of the substrate was to introduce module-specific stretchability and universal adhesiveness by regionally tuning the bulk molecular mobility and surface molecular polarity of a near-hermetic elastic polymer matrix. The packaging substrate can customize the deformation of different modules while avoiding delamination upon stretching up to 600%. Based on this substrate, we fabricated a fully stretchable bioelectronic device that can serve as a respiration sensor or an electric generator with an in vivo lifetime of 10 weeks. This substrate could be a versatile platform for device assembly.

Rugged Island-Bridge Inorganic Electronics Mounted on Locally Strain-Isolated Substrates

Various strain isolation strategies that combine rigid and stretchable regions for stretchable electronics were recently proposed, but the vulnerability of inorganic materials to mechanical stress has emerged as a major impediment to their performance. We report a strain-isolation system that combines heteropolymers with different elastic moduli (i.e., hybrid stretchable polymers) and utilize it to construct a rugged island-bridge inorganic electronics system. Two types of prepolymers were simultaneously cross-linked to form an interpenetrating polymer network at the rigid-stretchable interface, resulting in a hybrid stretchable polymer that exhibited efficient strain isolation and mechanical stability. The system, including stretchable micro-LEDs and microheaters, demonstrated consistent operation under external strain, suggesting that the rugged island-bridge inorganic electronics mounted on a locally strain-isolated substrate offer a promising solution for replacing conventional stretchable electronics, enabling devices with a variety of form factors.

Self-Powered Temperature Electronic Skin Based on Island-Bridge Structure and Bi-Te Micro-Thermoelectric Generator for Distributed Mini-Region Sensing

Thermoelectric (TE) effect based temperature sensor can accurately convert temperature signal into voltage without external power supply, which have great application prospects in self-powered temperature electronic skin (STES). But the fabrication of stretchable and distributed STES still remains a challenge. Here, a novel STES design strategy is proposed by combining flexible island-bridge structure with BiTe-based micro-thermoelectric generator (µ-TEG). Furthermore, a 4 × 4 vertical temperature sensor array with good stretchability and distributed sensing property has been fabricated for the first time. The interfacial chemical bonds located between the rigid islands (µ-TEG) and the flexible substrate (polydimethylsiloxane, PDMS) endow the STES with excellent stretchability, and its sensing performance remains unchanged under 30% strain (the maximum strain of human skin). Moreover, the STES sensing unit possesses high sensitivity (729 µV K-1 ), rapid response time (0.157 s), and high spatial resolution (2.75 × 2.75 mm2 ). As a proof of concept, this work demonstrates the application of the STES in the detection of mini-region heat sources in various scenarios including noncontact spatial temperature responsing, intelligent robotic thermosensing, and wearable temperature sensing. Such an inspiring design strategy is expected to provide guidance for the design and fabrication of wearable self-powered temperature sensors.

Highly stable and strain-insensitive metal film conductors via manipulating strain distribution

Metal film-based stretchable conductors are essential elements of flexible electronics for wearable, biomedical, and robotic applications, which require strain-insensitive high conductivity over a wide strain range and excellent cyclic stability. However, they suffer from serious electrical failure under monotonic and cyclic tensile loading at a small strain due to the uncontrolled film cracking behavior. Here, we propose a novel in-plane crack control strategy of engineering hierarchical microstructures to achieve outstanding electromechanical performance via harnessing the strain distribution in metal films. The wrinkles delay the crack initiation at undercuts which should be the most vulnerable sites during the stretching process. The surface protrusions/grooves/undercuts inhibit the crack propagation because of the effective strain redistribution. In addition, hierarchical microstructures significantly improve cyclic stability due to the strong interfacial adhesion and stable crack patterns. The metal film-based conductors exhibit ultrahigh strain-insensitive conductivity (1.7 × 107 S m-1), negligible resistance change (ΔR/R0 = 0.007) over an ultra-wide strain range (>200%), and excellent cyclic strain durability (>15 000 cycles at 100% strain). A range of metal films was explored to establish the universality of this strategy, including ductile copper and silver, as well as brittle molybdenum and high entropy alloy. We demonstrate the strain-insensitive electrical functionality of a metal film-based conductor in a flexible light-emitting diode circuit.

Strain-Driven Negative Resistance Switching of Conductive Fibers with Adjustable Sensitivity for Wearable Healthcare Monitoring Systems with Near-Zero Standby Power

Recently, one of the primary concerns in e-textile-based healthcare monitoring systems for chronic illness patients has been reducing wasted power consumption, as the system should be always-on to capture diverse biochemical and physiological characteristics. However, the general conductive fibers, a major component of the existing wearable monitoring systems, have a positive gauge-factor (GF) that increases electrical resistance when stretched, so that the systems have no choice but to consume power continuously. Herein, a twisted conductive-fiber-based negatively responsive switch-type (NRS) strain-sensor with an extremely high negative GF (resistance change ratio ≈ 3.9 × 108 ) that can significantly increase its conductivity from insulating to conducting properties is developed. To this end, a precision cracking technology is devised, which could induce a difference in the Young's modulus of the encapsulated layer on the fiber through selective ultraviolet-irradiation treatment. Owing to this technology, the NRS strain-sensors can allow for effective regulation of the mutual contact resistance under tensile strain while maintaining superior durability for over 5000 stretching cycles. For further practical demonstrations, three healthcare monitoring systems (E-fitness pants, smart-masks, and posture correction T-shirts) with near-zero standby power are also developed, which opens up advancements in electronic textiles by expanding the utilization range of fiber strain-sensors.

Sequentially Coated Wavy Nanowire Composite Transparent Electrode for Stretchable Solar Cells

Recent advances in fabricating stretchable and transparent electrodes have led to various techniques for establishing next-generation form-factor optoelectronic devices. Wavy Ag nanowire networks with large curvature radii are promising platforms as stretchable and transparent electrodes due to their high electrical conductivity and stretchability even at very high transparency. However, there are disadvantages such as intrinsic nonregular conductivity, large surface roughness, and nanowire oxidation in air. Here, we introduce electrically synergistic but mechanically independent composite electrodes by sequentially introducing conducting polymers and ionic liquids into the wavy Ag nanowire network to maintain the superior performance of the stretchable transparent electrode while ensuring overall conductivity, lower roughness, and long-term stability. In particular, plenty of ionic liquids can be incorporated into the uniformly coated conducting polymer so that the elastic modulus can be significantly lowered and sliding can occur at the nanowire interface, thereby obtaining the high mechanical stretchability of the composite electrode. Finally, as a result of applying the composite film as the stretchable transparent electrode of stretchable organic solar cells, the organic solar cell exhibits a high power conversion efficiency of 11.3% and 89% compared to the initial efficiency even at 20% tensile strain, demonstrating excellent stretching stability.