Soap Film Transfer Printing for Ultrathin Electronics

Flexible and stretchable electronics have attractive applications inaccessible to conventional rigid electronics. However, the mainstream transfer printing techniques have challenges for electronic films in terms of thickness and size and limitations for target substrates in terms of curvature, depth, and interfacial adhesion. Here a facile, damage-free, and contamination-free soap film transfer printing technique is reported that enables the wrinkle-free transfer of ultrathin electronic films, precise alignment in a transparent manner, and conformal and adhesion-independent printing onto various substrates, including those too topographically and adhesively challenging by existing methods. In principle, not only the pattern, resolution, and thickness of transferred films, but also the curvature, depth, and adhesion of target substrates are unlimited, while the size of transferred films can be as high as meter-scale. To demonstrate the capabilities of soap film transfer printing, pre-fabricated ultrathin electronics with multiple patterns, single micron resolution, sub-micron thickness, and centimeter size are conformably integrated onto the ultrathin web, ultra-soft cotton, DVD-R disk with the minimum radius of curvature of 131 nm, interior cavity of Klein bottle and dandelion with ultralow adhesion. The printed ultrathin sensors show superior conformabilities and robust adhesion, leading to engineering opportunities including electrocardiogram (ECG) signal acquisition and temperature measurement in aqueous environments.

Shape-Configurable MXene-Based Thermoacoustic Loudspeakers with Tunable Sound Directivity

Film-type shape-configurable speakers with tunable sound directivity are in high demand for wearable electronics. Flexible, thin thermoacoustic (TA) loudspeakers-which are free from bulky vibrating diaphragms-show promise in this regard. However, configuring thin TA loudspeakers into arbitrary shapes is challenging because of their low sound pressure level (SPL) under mechanical deformations and low conformability to other surfaces. By carefully controlling the heat capacity per unit area and thermal effusivity of an MXene conductor and substrates, respectively, it fabricates an ultrathin MXene-based TA loudspeaker exhibiting high SPL output (74.5 dB at 15 kHz) and stable sound performance for 14 days. Loudspeakers with the parylene substrate, whose thickness is less than the thermal penetration depth, generated bidirectional and deformation-independent sound in bent, twisted, cylindrical, and stretched-kirigami configurations. Furthermore, it constructs parabolic and spherical versions of ultrathin, large-area (20 cm × 20 cm) MXene-based TA loudspeakers, which display sound-focusing and 3D omnidirectional-sound-generating attributes, respectively.

Ultrathin Fiber-Mesh Polymer Thermistors

Flexible sensors enable on-skin and in-body health monitoring, which require flexible thermal protection circuits to prevent overheating and operate the devices safely. Here, ultrathin fiber-mesh polymer positive temperature coefficient (PTC) thermistors via electrospinning are developed. The fiber-type thermistors are composed of acrylate polymer and carbon nanofibers. The fibrous composite materials are coated with a parylene to form a core-sheath structure, which improves the repeatability of temperature characteristics. Approximately 5 µm thick fiber-type thermistors exhibit an increase in the resistance by three orders of magnitude within ≈2 °C and repeatable temperature characteristics for up to 400 cycles. The mesh structure enables the thermistor layer to be ultra-lightweight and transparent; the mesh-type thermistor operates with a fiber density of 16.5 µg cm^-2 , whose fiber layer has a transmittance of more than 90% in the 400-800 nm region. By fabricating the mesh thermistor on a 1.4 µm thick substrate, the thermistor operates without degradation when wrapped around a 280 µm radius needle. Furthermore, the gas-permeable property is demonstrated by fabricating the fibrous thermistor on a mesh substrate. The proposed ultrathin mesh polymer PTC thermistors form the basis for on-skin and implantable devices that are equipped with overheat prevention.

Wafer-Scale Fabrication of Ultrathin Flexible Electronic Systems via Capillary-Assisted Electrochemical Delamination

Electronic systems on ultrathin polymer films are generally processed with rigid supporting substrates during fabrication, followed by delamination and transfer to the targeted working areas. The challenge associated with an efficient and innocuous delamination operation is one of the major hurdles toward high-performance ultrathin flexible electronics at large scale. Herein, a facile, rapid, damage-free approach is reported for detachment of wafer-scale ultrathin electronic foils from Si wafers by capillary-assisted electrochemical delamination (CAED). Anodic etching and capillary action drive an electrolyte solution to penetrate and split the polymer/Si interface, leading to complete peel-off of the electronic foil with a 100% success rate. The delamination speed can be controlled by the applied voltage and salt concentration, reaching a maximum value of 1.66 mm s^-1 at 20 V using 2 m NaCl solution. Such a process incurs neither mechanical damage nor chemical contamination; therefore, the delaminated electronic systems remain intact, as demonstrated by high-performance carbon nanotube (CNT)-based thin-film transistors and integrated circuits constructed on a 5.5 cm × 5.0 cm parylene-based film with 4 µm thickness. Furthermore, the CAED strategy can be applied for prevalent polymer films and confers great flexibility and capability for designing and manufacturing diverse ultrathin electronic systems.

High-Performance, Ultrathin, Ultraflexible Organic Thin-Film Transistor Array Via Solution Process

Ultrathin organic thin-film transistors (OTFTs) have received extensive attention due to their outstanding advantages, such as extreme flexibility, good conformability, ultralight weight, and compatibility with low-cost and large-area solution-processed techniques. However, compared with the rigid substrates, it still remains a challenge to fabricate high-performance ultrathin OTFTs. In this study, a high-performance ultrathin 2,7-dioctyl[1]benzothieno[3,2-b][1]benzothiophene (C8-BTBT) OTFT array is demonstrated via a simple spin-coating method, with mobility as high as 11 cm2 V-1 s-1 (average mobility: 7.22 cm2 V-1 s-1 ), on/off current ratio of over 106 , switching current of >1 mA, and a good yield ratio as high as 100%. The ultrathin thickness at ≈380 nm and the ultralight weight at ≈0.89 g m-2 enable the free-standing OTFTs to imperceptibly adhere onto human skin, and even a damselfly wing without affecting its flying. More importantly, the OTFTs show good electrical characteristics and mechanical stability when conformed onto the curved surfaces and even folded in a book after 100 folding cycles. These results illustrate the broad application potential of this simply fabricated ultrathin OTFT in next-generation electronics such as foldable displays and wearable devices.

Extremely Vivid, Highly Transparent, and Ultrathin Quantum Dot Light-Emitting Diodes

Displaying information on transparent screens offers new opportunities in next-generation electronics, such as augmented reality devices, smart surgical glasses, and smart windows. Outstanding luminance and transparency are essential for such "see-through" displays to show vivid images over clear background view. Here transparent quantum dot light-emitting diodes (Tr-QLEDs) are reported with high brightness (bottom: ≈43 000 cd m^-2 , top: ≈30 000 cd m^-2 , total: ≈73 000 cd m^-2 at 9 V), excellent transmittance (90% at 550 nm, 84% over visible range), and an ultrathin form factor (≈2.7 µm thickness). These superb characteristics are accomplished by novel electron transport layers (ETLs) and engineered quantum dots (QDs). The ETLs, ZnO nanoparticle assemblies with ultrathin alumina overlayers, dramatically enhance durability of active layers, and balance electron/hole injection into QDs, which prevents nonradiative recombination processes. In addition, the QD structure is further optimized to fully exploit the device architecture. The ultrathin nature of Tr-QLEDs allows their conformal integration on various shaped objects. Finally, the high resolution patterning of red, green, and blue Tr-QLEDs (513 pixels in.^-1 ) shows the potential of the full-color transparent display.

Flexible Electronics: An Epidermal Stimulation and Sensing Platform for Sensorimotor Prosthetic Control, Management of Lower Back Exertion, and Electrical Muscle Activation (Adv. Mater. 22/2016)

The design of an ultrathin, conformal electronic device that integrates electrotactile stimulation with electromyography, temperature, and strain sensing in a single, simple platform is reported by J. A. Rogers and co-workers on page 4462. Demonstrated application possibilities include prosthetic control with sensory feedback, monitors, and stimulation signals related to lower back exertion, and electrical muscle stimulation with feedback control.

An Epidermal Stimulation and Sensing Platform for Sensorimotor Prosthetic Control, Management of Lower Back Exertion, and Electrical Muscle Activation

The design of an ultrathin, conformal electronic device that integrates electrotactile stimulation with electromyography, temperature, and strain sensing in a single, simple platform is reported. Experiments demonstrate simultaneous use of multiple modes of operation of this type of device in the sensorimotor control of robotic systems, in the monitoring of lower back exertion and in muscle stimulation.

25th anniversary article: A soft future: from robots and sensor skin to energy harvesters

Scientists are exploring elastic and soft forms of robots, electronic skin and energy harvesters, dreaming to mimic nature and to enable novel applications in wide fields, from consumer and mobile appliances to biomedical systems, sports and healthcare. All conceivable classes of materials with a wide range of mechanical, physical and chemical properties are employed, from liquids and gels to organic and inorganic solids. Functionalities never seen before are achieved. In this review we discuss soft robots which allow actuation with several degrees of freedom. We show that different actuation mechanisms lead to similar actuators, capable of complex and smooth movements in 3d space. We introduce latest research examples in sensor skin development and discuss ultraflexible electronic circuits, light emitting diodes and solar cells as examples. Additional functionalities of sensor skin, such as visual sensors inspired by animal eyes, camouflage, self-cleaning and healing and on-skin energy storage and generation are briefly reviewed. Finally, we discuss a paradigm change in energy harvesting, away from hard energy generators to soft ones based on dielectric elastomers. Such systems are shown to work with high energy of conversion, making them potentially interesting for harvesting mechanical energy from human gait, winds and ocean waves.