Flexible Embedded Metal Meshes by Sputter-Free Crack Lithography for Transparent Electrodes and Electromagnetic Interference Shielding.

A facile and novel fabrication method is demonstrated for creating flexible poly(ethylene terephthalate) (PET)-embedded silver meshes using crack lithography, reactive ion etching (RIE), and reactive silver ink. The crack width and spacing in a waterborne acrylic emulsion polymer are controlled by the thickness of the polymer and the applied stress due to heating and evaporation. Our innovative fabrication technique eliminates the need for sputtering and ensures stronger adhesion of the metal meshes to the PET substrate. Crack trench depths over 5 µm and line widths under 5 µm have been achieved. As a transparent electrode, our flexible embedded Ag meshes exhibit a visible transmission of 91.3% and sheet resistance of 0.54 Ω/sq as well as 93.7% and 1.4 Ω/sq. This performance corresponds to figures of merit (σDC/σOP) of 7500 and 4070, respectively. For transparent electromagnetic interference (EMI) shielding, the metal meshes achieve a shielding efficiency (SE) of 42 dB with 91.3% visible transmission and an EMI SE of 37.4 dB with 93.7% visible transmission. We demonstrate the highest transparent electrode performance of crack lithography approaches in the literature and the highest flexible transparent EMI shielding performance of all fabrication approaches in the literature. These metal meshes may have applications in transparent electrodes, EMI shielding, solar cells, and organic light-emitting diodes.

Hierarchical Structural Engineering of Ultrahigh-Molecular-Weight Polyethylene.

Nature has inspired the design of next-generation lightweight architectured structural materials, for example, nacre-bearing extreme impact and paw-pad absorbing energy. Here, a bioinspired functional gradient structure, consisting of an impact-resistant hard layer and an energy-absorbing ductile layer, is applied to additively manufacture ultrahigh-molecular-weight polyethylene (UHMWPE). Its crystalline graded and directionally solidified structure enables superior impact resistance. In addition, we demonstrate nonequilibrium processing, ultrahigh strain rate pulsed laser shock wave peening, which could trigger surface hardening for enhanced crystallinity and polymer phase transformation. Moreover, we demonstrate the paw-pad-inspired soft- and hard-fiber-reinforced composite structure to absorb the impact energy. The bioinspired design and nonequilibrium processing of graded UHMWPE shed light on lightweight engineering polymer materials for impact-resistant and threat-protection applications.

Magnetically hard ferrite nanoparticles synthesized through aerogel nanoreactor.

Magnetic ferrite materials have been extensively studied for a range of technological applications, such as magnetic motors, recording media, and millimetre-wave devices. In this context, the nanosized epsilon phase of Fe2O3 (ϵ-Fe2O3) attracts significant attention due to its high coercive field at room temperature. Here, we report the in-situ aerogel nanoreactor growth of magnetic ϵ-Fe2O3 nanoparticles, exhibiting a coercive field (Hc) of 4000 Oe. We show that the control of nanoreactor plays an important role in the growth of ϵ-Fe2O3 nanoparticles. The findings provide a versatile reaction pathway for the growth of magnetically hard ferrite nanoparticles.

Eutectic crystallized FePd nanoparticles for liquid metal magnet.

Magnetically hard nanoparticles have been widely explored in colloidal solution synthesis, while a high temperature-induced phase transformation is indispensable to achieve its high magnetocrystalline anisotropy. However, a long-standing challenge of magnetic nanoparticles is the inaccessibility of size-controlled growth without sintering-induced agglomeration. Here, we report a universal one-pot eutectic reaction scheme of magnetically hard FePd nanoparticles, in which the crystallization conditions are critical for its magnetic performance. We demonstrate that the stoichiometry between transition metal and eutectic salt and sintering temperature can play an important role in the magnetic coercivity of FePd nanoparticles. In addition, gallium liquid metal is employed as the conductivity filler for the formation of a magnetorheological fluid after mixing with metallic FePd nanoparticles. The liquid composite shows a high metallic and thermal conductivity as an unconventional cooling metallic ferrofluid conductor, and we further demonstrate its potential application in sensors, conductors and thermal interfaces.

An All-Ceramic, Anisotropic, and Flexible Aerogel Insulation Material.

To exploit the high-temperature superinsulation potential of anisotropic thermal management materials, the incorporation of ceramic aerogel into the aligned structural networks is indispensable. However, the long-standing obstacle to exploring ultralight superinsulation ceramic aerogels is the inaccessibility of its mechanical elasticity, stability, and anisotropic thermal insulation. In this study, we report a recoverable, flexible ceramic fiber-aerogel composite with anisotropic lamellar structure, where the interfacial cross-linking between ceramic fiber and aerogel is important in its superinsulation performance. The resulting ultralight aerogel composite exhibits a density of 0.05 g/cm3, large strain recovery (over 50%), and low thermal conductivity (0.0224 W m-1 K-1), while its hydrophobicity is achieved by in situ trichlorosilane coating with the water contact angle of 135°. The hygroscopic tests of such aerogel composites demonstrate a reversible thermal insulation. The mechanical elasticity and stability of the anisotropic composites, with its soundproof performance, shed light on the low-cost superelastic aerogel manufacturing with scalability for energy saving building applications.

Rare-earth-free magnetically hard ferrous materials.

Permanent magnets, especially rare-earth based magnets, are widely used in energy-critical technologies in many modern applications, involving energy conversion and information technologies. However, the environmental impact and strategic supplies of rare-earth elements hamper the long-term development of permanent magnets. Hence, there is a surge of interest to expand the search for rare-earth-free magnets with a large energy product (BH)max. Among these rare-earth-free magnets, iron-based permanent magnets emerge as some of the most promising candidates due to their abundance and magnetic performance. In this review, we present a summary of iron-based permanent magnets from materials synthesis to their magnetic properties.