Abstract
In this work we present the concept of electroplated conductive elastomers and ablative multi-layer and multi-material laser-assisted manufacturing to enable a largely automated, computer-aided manufacturing process of stretchable electronics and sensors. Therefore, the layers (conductive and non-conductive elastomers as well as metal layers for contacting) are first coated over the entire surface (doctor blade coating and electroplating) and then selectively removed with a CO2 or a fiber laser. These steps are repeated several times to achieve a multi-layer-structured design. Is it not only possible to adjust and improve the work previously carried out manually, but also completely new concepts such as fine through-plating between the layers to enable much more compact structures become possible. In addition, metallized areas allow the direct soldering of electronic components and thus a direct connection between conventional and stretchable electronics. As an exemplary application, we have used the process for manufacturing a thin and surface solderable pressure sensor with a silicone foam dielectric and a stretchable circuit board.
Highlights
The availability of stretchable conductive materials is a key requirement for the further development of rigid circuit board-based electronics toward soft and wearable systems, when considering conducting paths themselves and advanced components such as stretchable sensors and actuators
When using heat-resistant elastomers, such as silicones, soldering process temperatures of over 200 °C are possible without material degeneration
The advantage of the electroplating process described in this work is the combination of a conductive particle–elastomer composite with a highly conductive, flexible as well as solderable metal layer
Summary
The availability of stretchable conductive materials is a key requirement for the further development of rigid circuit board-based electronics toward soft and wearable systems, when considering conducting paths themselves and advanced components such as stretchable sensors and actuators. Despite the existence of intrinsic conductive polymers, filling non-conductive polymers with conductive particles remains a scalable and cost-effective way to gain conductivity for any polymer, including elastomers. This route has been used to develop, among others, highly stretchable composite electrodes consisting of polydimethylsiloxane (PDMS) and silver-coated copper flakes [1]. Stretchable electronic systems are only conceivable as a hybrid composition of conventional semiconductors and intermediate elastic conductor paths. This composition requires good mechanical and electrical bonding between rigid and soft components. In addition to the integration of conventional components, multi-layer and precisely structured designs based on elastic materials are an important prerequisite for the realization of stretchable electronics and sensors, analogous to conventional printed circuit boards
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