Developing the Surface Chemistry of Transparent Butyl Rubber for Impermeable Stretchable Electronics

Transparent butyl rubber is a new elastomer that has the potential to revolutionize stretchable electronics due to its intrinsically low gas permeability. Encapsulating organic electronic materials and devices with transparent butyl rubber protects them from problematic degradation due to oxygen and moisture, preventing premature device failure and enabling the fabrication of stretchable organic electronic devices with practical lifetimes. Here, we report a methodology to alter the surface chemistry of transparent butyl rubber to advance this material from acting as a simple device encapsulant to functioning as a substrate primed for direct device fabrication on its surface. We demonstrate a combination of plasma and chemical treatment to deposit a hydrophilic silicate layer on the transparent butyl rubber surface to create a new layered composite that combines Si-OH surface chemistry with the favorable gas-barrier properties of bulk transparent butyl rubber. We demonstrate that these surface Si-OH groups react with organosilanes to form self-assembled monolayers necessary for the deposition of electronic materials, and furthermore demonstrate the fabrication of stretchable gold wires using nanotransfer printing of gold films onto transparent butyl rubber modified with a thiol-terminated self-assembled monolayer. The surface modification of transparent butyl rubber establishes this material as an important new elastomer for stretchable electronics and opens the way to robust, stretchable devices

Metal-Interface-Elastomer (MINE) Structures for Stretchable Electronics

The future of soft, conformable, and robust wearable electronics will require elastomers to provide mechanical stabilization, a soft surface to interact with human wearers, and a crucial physical barrier to protect stretchable devices from the environment. It is a difficult challenge, however, for a single elastomer to fulfill each of these needs. Here, we present a new approach that fuses a membrane of poly(dimethylsiloxane) (PDMS) onto the surface of a transparent butyl rubber (T-IIR) substrate using an organosilane-based molecular glue. The resulting membrane-interface-elastomer (MINE) structures uniquely combine the surface chemistry of PDMS with the intrinsically low gas permeability of T-IIR for the fabrication of robust stretchable devices. Our most intriguing finding, however, is that the T-IIR-PDMS interface, buried microns below the PDMS surface, exerts a remarkable influence on metal films deposited on the PDMS membrane surface from below, improving stretching and conductance performance by orders of magnitude

Stretchable Ultrasheer Fabrics as Semitransparent Electrodes for Wearable Light-Emitting e-Textiles with Changeable Display Patterns

Despite the development throughout human history of a wealth of textile materials and structures, the porous structures and non-planar surfaces of textiles are often viewed as problematic for the fabrication of wearable e-textiles and smart clothing. Here, we demonstrate a new textile-centric design paradigm in which we use the textile structure as an integral part of wearable device design. We coat the open framework structure of an ultrasheer knitted textile with a conformal gold film using solution-based metallization to form gold-coated ultrasheer electrodes that are highly conductive (3.6 ± 0.9 Ω/sq) and retain conductivity to 200% strain with R/R0 \u3c 2. The ultrasheer electrodes produce wearable, highly stretchable light-emitting e-textiles that function to 200% strain. Stencil printing a wax resist provides patterned electrodes for patterned light emission; furthermore, incorporating soft-contact lamination produces light-emitting textiles that exhibit, for the first time, readily changeable patterns of illumination

Solution Deposition of Conformal Gold Coatings on Knitted Fabric for E-Textiles and Electroluminescent Clothing

The vision for wearable electronics involves creating an imperceptible boundary between humans and devices. Integrating electronic devices into clothing represents an important path to this vision; however, combining conductive materials with textiles is challenging due to the porous structure of knitted textiles. Stretchability depends on maintaining the void structure between the yarns of the fabric; filling these voids with conductive materials stiffens the textile and can lead to detrimental cracking. The authors demonstrate the solution-based metallization of a knitted textile that conformally coats individual fibers with gold, leaving the void structure intact. The resulting gold-coated textile is highly conductive, with a sheet resistance of 1.07 Wsq-1in the course direction. The resistance decreases by 80% when the fabric is stretched to 15% strain, and remains at this value to 160% strain. This outstanding combination of stretchability and conductivity is accompanied by durability to wearing, sweating, and washing. Low-cost screen printing of a wax resist is demonstrated to produce patterned gold textiles suitable for electrically connecting discrete devices in clothing. The fabrication of electroluminescent fabric by depositing layers of device materials onto the gold-coated textile is furthermore demonstrated, intimately merging device functionality with textiles for imperceptible wearable devices

Ready-to-wear strain sensing gloves for human motion sensing

Integrating soft sensors with wearable platforms is critical for sensor-based human augmentation, yet the fabrication of wearable sensors integrated into ready-to-wear platforms remains underdeveloped. Disposable gloves are an ideal substrate for wearable sensors that map hand-specific gestures. Here, we use solution-based metallization to prepare resistive sensing arrays directly on off-the-shelf nitrile butadiene rubber (NBR) gloves. The NBR glove acts as the wearable platform while its surface roughness enhances the sensitivity of the overlying sensing array. The NBR sensors have a sheet resistance of 3.1 ± 0.6 Ω/sq and a large linear working range (two linear regions ≤70%). When stretched, the rough NBR substrate facilitates microcrack formation in the overlying metal, enabling high gauge factors (62 up to 40% strain, 246 from 45 - 70% strain) that are unprecedented for metal film sensors. We apply the sensing array to dynamically monitor gestures for gesture differentiation and robotic control

Protocol for fabricating electroless nickel immersion gold strain sensors on nitrile butadiene rubber gloves for wearable electronics

This protocol describes the fabrication of patterned conductive gold films on nitrile butadiene rubber (NBR) gloves for wearable strain sensors using electroless nickel immersion gold (ENIG) plating, a solution-based metallization technique. The resulting NBR/ENIG films are strain sensitive; resistance measurements of a patterned sensing array can be used to map human hand motions. This protocol also describes challenges related to the ENIG process and troubleshooting steps to achieve conformal gold films for strain sensing over a large working range. For complete details on the use and execution of this protocol, please refer to Mechael et al. (2021)

Transparent, Stretchable, and Conductive SWNT Films Using Supramolecular Functionalization and Layer-by-Layer Self-Assembly

We demonstrate films of single-walled carbon nanotubes (SWNTs) on the elastomer polydimethylsiloxane (PDMS) that are stretchable, conductive, and transparent. Our fabrication method uses the supramolecular functionalization of SWNTs with conjugated polyelectrolytes to generate aqueous dispersions of positively- and negatively-charged SWNTs, followed by layer-by-layer self-assembly onto a PDMS substrate. Adding bilayers of positively- and negatively-charged SWNTs to the surface causes the sheet resistance and the % transmittance of the film to both progressively decrease. The sheet resistance decreases sharply in the first five bilayers as the layer-by-layer process efficiently establishes the percolation network, whereas the % transmittance declines more gradually. Films with 25 bilayers are transparent (75% at 550 nm) and conductive (560 ± 90 ohms/sq). The combination of electrostatic and pi-stacking forces very effectively bind the SWNTs within the film, producing smooth film surfaces (root-mean-square roughness of 18 nm) and enabling the films to remain conductive up to 80% elongation. We demonstrate the use of the SWNT films as transparent conductive electrodes in light-emitting devices and as soft strain sensors that are both wearable and transparent

A Self-Assembled, Low-Cost, Microstructured Layer for Extremely Stretchable Gold Films

We demonstrate a simple, low-cost, and green approach to deposit a microstructured coating on the silicone elastomer polydimethylsiloxane (PDMS) that can be coated with gold to produce highly stretchable and conductive films. The microstructured coating is fabricated using an aqueous emulsion of poly(vinyl acetate) (PVAc): common, commercially available white glue. The aqueous glue emulsion self-assembles on the PDMS surface to generate clustered PVAc globules, which can be conformally coated with gold. The microstructured surface provides numerous defect sites that localize strain when the structure is stretched, resulting in the initiation of numerous microcracks. As the structure is further elongated, the microcracks interact with one another, preventing long-range crack propagation and thus preserving the conduction pathway. The resistance of PDMS/glue/gold structures remains remarkably low (23x the initial resistance) up to 65% elongation, making these structure useful as stretchable interconnects. Decreasing the concentration of the PVAc aqueous emulsion reduces the density of defect sites of the microstructure, which increases the change in resistance of the gold films with stretching. In this way, we can tune the resistance changes of the PDMS/glue/gold structures and increase their sensitivity to strain. We demonstrate the use of these structures as wearable, soft strain sensors