Laser-Written Borders for Shape-Controlled Soft Electronics
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Solution Overview
Problem
The challenge in soft electronics manufacturing lies in using materials with elastomeric properties in additive manufacturing, as they are traditionally difficult to work with due to issues like flow and spreading during the deposition process, which affects the functionality of stretchable and flexible devices.
Innovation Solution
A hybrid manufacturing method involving laser writing a border on a substrate to create an internal and external zone, where the material is deposited in an uncured state and partially cured within the internal zone, with the border impeding the flow of material to allow sufficient curing time before adding subsequent layers, using materials like polyimide and polydimethylsiloxane, and incorporating laser-induced porous graphene for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomeric materials are used in additive manufacturing, then the device becomes stretchable and flexible, but the material flows and spreads during deposition making it difficult to maintain shape and precision
Solution Approach 1:
A border structure is created on the substrate before material deposition. This border acts as a pre-established constraint that prevents the elastomeric material from flowing beyond designated areas during deposition, enabling precise shape control while maintaining the material's stretchable and flexible properties
Solution Approach 2:
The border serves as an intermediary element between the substrate and the elastomeric material. It mediates the interaction by providing a physical barrier that controls material flow, allowing the material to be deposited in controlled patterns without requiring additional adhesives or complex processing
2Shape
If the material is deposited in uncured state to allow flow and spreading, then the material can conform to the substrate, but the material may flow beyond intended boundaries affecting device functionality
Solution Approach 1:
The border is formed on the substrate before material deposition, creating predetermined boundaries that will contain the uncured material. This preliminary structure ensures that when the material is deposited in its flowable uncured state, it can conform to the substrate within the border-defined area without flowing beyond intended boundaries
Solution Approach 2:
The substrate surface is segmented into distinct deposition zones by the border structure. This segmentation creates separate internal zones where material can be deposited and controlled independently, preventing unwanted flow between different functional areas of the device
3Strength
If additional adhesives are used to improve layer bonding, then the adhesion between layers improves, but the device complexity and number of materials increases
Solution Approach 1:
The border structure serves multiple functions simultaneously: it acts as a flow barrier, a substrate modification, and a bonding interface. By merging these functions into a single element, the need for separate adhesives is eliminated, reducing device complexity while maintaining strong layer bonding
Solution Approach 2:
The border is designed as a multi-functional element that provides flow impediment, surface modification for enhanced adhesion, and structural definition. This universal element replaces what would traditionally require multiple separate materials including adhesives, simplifying the overall device architecture
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the successful formation of multi-layered, flexible electronic devices with improved adhesion and bonding between layers, allowing for the use of non-thixotropic materials and maintaining functionality even when deformed or stretched, without the need for additional adhesives.
Implementation Method 1
laser writing a border on a receiving surface of a substrate, the border being a part of the substrate that is changed in its material properties by the laser writing
Implementation Method 2
The substrate may comprise polyimide, and the laser writing may comprise forming laser-induced porous graphene as the border
Implementation Method 3
depositing a material in the internal zone, the material being deposited in an uncured or initially liquid state on the receiving surface, wherein a flow of the material from the internal zone towards the external zone is impeded by the border
Implementation Method 4
The border may comprise an impeding surface on the receiving surface, wherein the flow of the material across the impeding surface is slower than the flow of the material across the substrate or entirely stopped
Implementation Method 5
at least partially curing or otherwise at least partially modifying or solidifying the material in the internal zone, the at least partially cured, modified or solidified material forming a layer
Implementation Method 6
The method may further comprise: using laser heating to form an interface area on the layer, the layer being hydrophobic, the interface area being non-hydrophobic properties
Data Source
AI summary
A hybrid manufacturing method and a device made thereby. The method includes: laser writing a border on a receiving surface of a substrate, the border defining an internal zone inside the border and an external zone outside the border, the border being a part of the substrate that is changed in its material properties by the laser writing; depositing a material in the internal zone, the material being deposited in an uncured state on the receiving surface, wherein a flow of the material from the internal zone towards the external zone is impeded by the border; and at least partially curing the material in the internal zone, the at least partially cured material forming a layer.