Highly Robust and Strain-Resilient Thin Film Conductors Featuring Brittle Materials
Kai Chen, Linyuan Zhang, Kai Wu, Chao Yang, Ruihong Wang, Canhua Xu, Jinyu Zhang, Gang Liu, Jun Sun
Abstract
Stretchable conductors with stable electrical conductivity under various deformations are essential for wearable electronics, soft robots, and biointegrated devices. However, brittle film-based conductors on elastomeric substrates often suffer from unexpected electrical disconnection due to the obvious mechanical incompatibility between stiff films and soft substrates. We proposed a novel out-of-plane crack control strategy to achieve the strain-insensitive electrical performance of thin-film-based conductors, featuring conductive brittle materials, including nanocrystalline metals (Cu, Ag, Mo) and transparent oxides (ITO). Our metal film-based conductors exhibit an ultrahigh initial conductivity (1.3 × 10 5 S cm –1 ) and negligible resistance change ( R / R 0 = 1.5) over wide strain range from 0 to 130%, enabled by film-induced substrate cracking and liquid metal-induced electrical self-repairing. They could function well under multimodal deformations (stretching, bending, and twisting) and severe mechanical damage (cutting and puncturing). We demonstrated the strain-resilient electrical functionality of metal film-based conductors in a flexible light-emitting diode display that shows high mechanical compliance.