Self-Healing Conductive Elastomer Film With Laser-Activated Layers
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Solution Overview
Problem
Existing self-healing elastomer materials for electrically conductive multilayer structures face limitations in electrical conductivity, stretchability, cyclic fatigue resistance, and durability under mechanical and environmental stress, leading to catastrophic failures in soft electronics devices.
Innovation Solution
A method for preparing a multilayer self-healing electrically conducting elastomer film using an insulating substrate layer, a self-healing elastomer layer, and a self-healing liquid metal elastomer composite layer, activated by laser to enhance conductivity, with optional intermediate layers for improved adhesion and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high conductivity materials are used, then electrical conductivity improves, but stretchability and cyclic fatigue resistance deteriorate
Solution Approach 1:
The patent segments the functional requirements into separate layers: the self-healing elastomer layers provide stretchability and cyclic fatigue resistance, while the conductive layers (liquid metal or conductive polymer) provide electrical conductivity. This segmentation allows each layer to optimize its specific function without compromising the other properties, enabling the composite structure to achieve both high conductivity and mechanical flexibility.
2Ease of manufacture
If direct printing of liquid metal on substrate is attempted, then manufacturing simplicity is maintained, but substrate material incompatibility prevents successful application
Solution Approach 1:
The patent introduces a self-healing elastomer intermediate layer between the substrate and the liquid metal conductive layer. This intermediary layer serves as a compatible interface that allows the liquid metal to be successfully applied and printed on diverse substrate materials (such as silicone rubber, PDMS, or other elastomers) without direct contact issues. The intermediate layer enhances adhesion and compatibility, enabling straightforward printing processes on various substrate types.
3Reliability
If macroscopic damage occurs in stretchable interconnections, then device failure propagates catastrophically, but use of self-healing layers adds structural complexity
Solution Approach 1:
The patent incorporates self-healing elastomer layers in advance within the multilayer structure to prevent catastrophic failure. These layers are designed to heal microcracks and damage automatically through the self-healing mechanism of the elastomer material, cushioning against damage propagation before it can lead to device failure. This beforehand cushioning approach reduces the need for complex damage detection and repair systems.
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
The method significantly enhances electrical conductivity by 1.5-5.0 times and extends stretching range, improves cyclic fatigue resistance, and ensures durable performance under mechanical stress, making it suitable for soft electronics applications.
Implementation Method 1
activating the surface of the layer comprising a self-healing electrically conducting liquid metal elastomer composite with laser to improve electric conductivity of the layer
Implementation Method 2
The obtained materials and products can be used in a variety of different electronics solutions, such as in electronic devices, components, structures and/or parts thereof. More particularly, the present methods and materials use autonomously self-healing elastomers
Implementation Method 3
crosslinking the first layer comprising a self-healing elastomer with the electrically insulating substrate layer
Data Source
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AI summary
A method for preparing a multilayer self-healing electrically conducting elastomer film (10), the method comprising providing (12a) an electrically insulating substrate layer (12) comprising an elastomer matrix, applying (14a) a first layer (14) comprising a self-healing elastomer on top of the electrically insulating substrate layer (12), crosslinking (16) the first layer (14) comprising a self-healing elastomer with the electrically insulating substrate layer (12), applying (18a) a layer (18) comprising a self-healing electrically conducting liquid metal elastomer composite comprising gallium as main phase on top of the first layer (14) comprising a self-healing elastomer, and activating (20) the surface of the layer (18) comprising a self-healing electrically conducting liquid metal elastomer composite with laser to improve electric conductivity of the layer. A multilayer self-healing electrically conducting elastomer film (10), comprising an electrically insulating substrate layer comprising an elastomer matrix (12), a first layer (14) comprising a self-healing elastomer crosslinked with the electrically insulating substrate layer, and a layer (18) comprising a self-healing electrically conducting liquid metal elastomer composite comprising gallium as main phase on top of the first layer comprising a self-healing elastomer. A method for preparing an electronic device. An electronic device comprising the multilayer self-healing electrically conducting elastomer film (10).