Self-assembling bilayer wiring with highly conductive liquid metal and insulative ion gel layers.

Ga-based liquid metals (LMs) are expected to be suitable for wiring highly deformable devices because of their high electrical conductivity and stable resistance to extreme deformation. Injection and printed wiring, and wiring using LM-polymer composites are the most popular LM wiring approaches. However, additional processing is required to package the wiring after LM patterning, branch and interrupt wiring shape, and ensure adequate conductivity, which results in unnecessary wiring shape changes and increased complexity of the wiring methods. In this study, we propose an LM-polymer composite comprising LM particles and ion gel as a flexible matrix material with low viscosity and specific gravity before curing. Moreover, the casting method is used for wire patterning, and the material is cured at room temperature to ensure that the upper insulative layer of the ion gel self-assembles simultaneously with the formation of LM wiring in the lower layer. High conductivity and low resistance change rate of the formed wiring during deformation are achieved without an activation process. This ion gel-LM bilayer wiring can be used for three-dimensional wiring by stacking. Furthermore, circuits fabricated using ion gel-LM bilayer wiring exhibit stable operation. Therefore, the proposed method can significantly promote the development of flexible electronic devices.

Stretchable Gas Barrier Films Using Liquid Metal toward a Highly Deformable Battery.

Highly deformable batteries that are flexible and stretchable are important for the next-generation wearable devices. Several studies have focused on the stable operation and life span of batteries. On the other hand, there has been less focus on the packaging of highly deformable batteries. In wearable devices, solid-state or pouch lithium-ion batteries (LIBs) packaged in aluminum (Al)-laminated films, which protect against moisture and gas permeation, are used. Stretchable elastomer materials are used as the packaging films of highly deformable batteries; however, they are extremely permeable to gas and moisture. Therefore, a packaging film that provides high deformability along with gas and moisture barrier functionalities is required for the stable operation of highly deformable batteries used in ambient conditions. In this study, a stretchable packaging film with high gas barrier functionality is developed successfully by coating a thin layer of liquid metal onto a gold (Au)-deposited thermoplastic polyurethane film using the layer-by-layer method. The film exhibits excellent oxygen gas impermeability under mechanical strain and extremely low moisture permeability. It shows high impermeability along with high mechanical robustness. Using the proposed stretchable gas barrier film, a highly deformable LIB is assembled, which offers reliable operation in air. The operation of the highly deformable battery is analyzed by powering LEDs under mechanical deformations in ambient conditions. The proposed stretchable packaging film can potentially be used for the development of packaging films in advanced wearable electronic devices.

Direct Wiring of Liquid Metal on an Ultrasoft Substrate Using a Polyvinyl Alcohol Lift-off Method.

In recent years, wiring and system construction on ultrasoft materials such as biological tissues and hydrogels have been proposed for advanced wearable devices, implantable devices, and soft robotics. Among the soft conductive materials, Ga-based liquid metals (LMs) are both biocompatible and ultrasoft, making them a good match for electrodes on the ultrasoft substrates. However, gels and tissues are softer and less wettable to the LMs than conventional soft substrates such as Ecoflex and polydimethylsiloxane. In this study, we demonstrated the transfer of LM paste composed of Ga-based LM and Ni nanoparticles onto ultrasoft substrates such as biological tissue and gels using sacrificial polyvinyl alcohol (PVA) films. The LM paste pattern fabricated on the PVA film adhered to the ultrasoft substrate along surface irregularities and was transferred without being destroyed by the PVA film before the PVA's dissolution in water. The minimum line width that could be wired was approximately 165 µm. Three-dimensional wiring, such as the helical structure on the gel fiber surface, is also possible. Application of this transfer method to tissues using LM paste wiring allowed the successful stimulation of the vagus nerve in rats. In addition, we succeeded in transferring a temperature measurement system fabricated on a PVA film onto the gel. The connection between the solid-state electrical element and the LM paste was stable and maintained the functionality of the temperature-sensing system. This fundamental study of wiring fabrication and system integration can contribute to the development of advanced electric devices based on ultrasoft substrates.