Fabrice Axisa

Adhesion enhancement by a dielectric barrier discharge of PDMS used for flexible and stretchable electronics

Currently, there is a strong tendency to replace rigid electronic assemblies by mechanically flexible and stretchable equivalents. This emerging technology can be applied for biomedical electronics, such as implantable devices and electronics on skin. In the first step of the production process of stretchable electronics, electronic interconnections and components are encapsulated into a thin layer of polydimethylsiloxane (PDMS). Afterwards, the electronic structures are completely embedded by placing another PDMS layer on top. It is very important that the metals inside the electronic circuit do not leak out in order to obtain a highly biocompatible system. Therefore, an excellent adhesion between the 2 PDMS layers is of great importance. However, PDMS has a very low surface energy, resulting in poor adhesion properties. Therefore, in this paper, PDMS films are plasma treated with a dielectric barrier discharge (DBD) operating in air at medium pressure (5.0 kPa). Contact angle and XPS measurements reveal that plasma treatment increases the hydrophilicity of the PDMS films due to the incorporation of silanol groups at the expense of methyl groups. T-peel tests show that plasma treatment rapidly imparts adhesion enhancement, but only when both PDMS layers are plasma treated. Results also reveal that it is very important to bond the plasma-treated PDMS films immediately after treatment. In this case, an excellent adhesion is maintained several days after treatment. The ageing behaviour of the plasma-treated PDMS films is also studied in detail: contact angle measurements show that the contact angle increases during storage in air and angle-resolved XPS reveals that this hydrophobic recovery is due to the migration of low molar mass PDMS species to the surface.

Design of an Implantable Slot Dipole Conformal Flexible Antenna for Biomedical Applications

We present a flexible folded slot dipole implantable antenna operating in the Industrial, Scientific, and Medical (ISM) band (2.4-2.4835 GHz) for biomedical applications. To make the designed antenna suitable for implantation, it is embedded in biocompatible Polydimethylsiloxane (PDMS). The antenna was tested by immersing it in a phantom liquid, imitating the electrical properties of the human muscle tissue. A study of the sensitivity of the antenna performance as a function of the dielectric parameters of the environment in which it is immersed was performed. Simulations and measurements in planar and bent state demonstrate that the antenna covers the complete ISM band. In addition, Specific Absorption Rate (SAR) measurements indicate that the antenna meets the required safety regulations.

Design and Manufacturing of Stretchable High-Frequency Interconnects

The increasing number of biomedical applications for electronic systems have led to the need for stretchable electronics in order to significantly enhance the comfort of the user. This paper describes the design and manufacturing process of new stretchable high-frequency interconnects with meander-shaped conductors in a coplanar waveguide topology. The novel interconnects are produced based on laser-ablation of a copper foil, which is then embedded in a highly stretchable bio-compatible silicone material. Measurements on prototypes of the designed stretchable high-frequency interconnects revealed a maximal magnitude of -14 dB for the reflection coefficient and a minimal magnitude of -4 dB for the transmission coefficient in the frequency band up to 3 GHz. The influence of stretch on the performance of the high-frequency interconnects was analyzed using a stretch testing machine. The results showed that nor the magnitude, neither the phase of the transmission coefficient was influenced by elongations up to 20%.

In situ observations on deformation behavior and stretching-induced failure of fine pitch stretchable interconnect

Electronic devices capable of performing in extreme mechanical conditions such as stretching, bending, or twisting will improve biomedical and wearable systems. The required capabilities cannot be achieved with conventional building geometries, because of structural rigidity and lack of mechanical stretchability. In this article, a zigzag-patterned structure representing a stretchable interconnect is presented as a promising type of building block. In situ experimental observations on the deformed interconnect are correlated with numerical analysis, providing an understanding of the deformation and failure mechanisms. The experimental results demonstrate that the zigzag-patterned interconnect enables stretchability up to 60% without rupture. This stretchability is accommodated by in-plane rotation of arms and out-of-plane deformation of crests. Numerical analysis shows that the dominating failure cause is interfacial in-plane shear stress. The plastic strain concentration at the arms close to the crests, obtained by numerical simulation, agrees well with the failure location observed in the experiment.

Elastic and Conformable Electronic Circuits and Assemblies using MID in polymer

For user comfort reasons, electronic circuits for implantation in the human body or for use as smart clothes should ideally be soft, stretchable and elastic. In this contribution the initial results of an MID (moulded interconnect device) technology will be presented, showing the feasibility of functional stretchable electronic circuits. In the developed technology rigid or flexible standard components are interconnected by meander shaped electroplated metallic wires and embedded by molding in a stretchable substrate polymer, like silicone rubber or polyurethane. The meander design was supported by mechanical simulations in order to minimize the stress in the metal during deformation. In this way reliable stretchability of the circuits above 100% has been demonstrated. A simple stretchable thermometer circuit with 4 components embedded in Dow Corning Silasticreg PDMS silicone material has been built and proper operation has been demonstrated.

Laser based fast prototyping methodology of producing stretchable and conformable electronic systems

For user comfort and reliability reasons, electronic circuits for human body related applications should ideally be soft, elastic and stretchable, for smart textile application, but also for applications which need a high level of biocompatibility. We are developing several roll-to roll technologies using MID (Molded Interconnect Device) and low cost standard PCB technology (Printed Circuit Board) to produce soft, stretchable, human-compatible packaging. All those technologies are based on a sacrificial layer on where meander shaped interconnections are patterned. Those stretchable interconnections are connecting together non-stretchable functional islands on where SMD components are soldered. All the system is then embedded in stretchable polymer matrix, silicone rubber or polyurethane. All these technologies are using standards methodologies for PCB productions (lamination, photolithography, copper etching, reflow oven lead free soldering). A fast prototyping technology has been developed to ease the development of stretchable electronic circuits. Less than 1 day is necessary from CAD design to finalization: Rigid or flexible standard components or electronic sub-systems are interconnected with YAG laser shaped meander interconnections and molded in silicone rubber afterwards. From any kind of flexible circuit, stretchable circuit can be produced using this methodology. The stretchable meander interconnection can be stretched more than 100% and can sustain at least 3000 cycles at 20% of deformation. This paper presents a general overview of stretchable electronic process, a detailed view of the fast prototyping technology using YAG laser cutting, and the demonstrators developed in the frame of the European project STELLA (Stretchable Electronic for large area) [7] and in the Belgian project SWEET (Stretchable and washable electronic in textile) [8] and BIOFLEX (Biocompatible stretchable electronic system) [9].

Elastic Interconnects for Stretchable Electronic Circuits using MID (Moulded Interconnect Device) Technology

An MID (Moulded Interconnect Device) technology was developed for the production of elastic electronic interconnections. The stretchability is obtained using tortuous horseshoe shaped metallic wiring, embedded in a matrix of PDMS (poly dimethyl siloxane). In this way stretchable interconnects have been realized, consisting of 4 micron thick gold wires, embedded in 250 − 500 μm thick silicone material. . Stretchable interconnections, realised with this technology, have a maximum stretchability above 100%, with a stable resistivity of about 1.5 Ω per running cm for a track width of 100μm. A first simple operating stretchable electronic circuit has been fabricated, consisting of a blue LED driven by stretchable wiring. The technology is under development for use in biomedical applications in the first place, but has potential to be extended for various other applications like smart textiles, robotic skins, etc.

Shape-memory anchoring system for bladder sensors

In this work, we propose the use of shape-memory polymer as an anchoring system for a bladder sensor. The anchoring system was designed from a biomedical biodegradable water-based poly(ester-urethane) produced in an aqueous environment by using isophorone diisocyanate/hydrazine (hard segment) and poly(caprolactone diol)/2,2-bis (hydroxymethyl) propionic acid (soft segment) as the main reagents. Tensile strength and elongation-at-break deterioration upon degradation in synthetic urine were investigated. In-body shape recovery was simulated and measured in synthetic urine. Results indicated that shape recovery can occur at body temperature and expulsion of the sensor by the body along with urine may occur through the combined effect of urine hydrolytic attack and compression exerted by the bladder walls.

Improved Stretchable Electronics Technology for Large Area Applications

A novel technology for stretchable electronics is presented which can be used for the realization of wearable textile electronics and biomedical implants. It consists of rigid or flexible component islands interconnected with stretchable meander-shaped copper conductors embedded in a stretchable polymer, e.g. PDMS. The technology uses standard PCB manufacturing steps and liquid injection molding techniques to achieve a robust and reliable product. Due to the stretchable feature of the device, conductors and component islands should be able to withstand a certain degree of stress to guarantee the functionality of the system. Although the copper conductors are meander-shaped in order to minimize the local plastic strain, the lifetime of the system is still limited by the occurrence of crack propagation through the copper, compromising the connectivity between the functional islands. In order to improve the lifetime of the conductors, the most important feature of the presented technology is the use of spin-on polyimide as a mechanical support for the stretchable interconnections and the functional flexible islands. In this way, every stretchable copper connection is supported by a 20μm layer of polyimide being shaped in the same manner as the above laying conductor. The grouped SMD components and straight copper tracks on the functional islands are also supported by a complete 20 μm polyimide layer. By use of the polyimide, the reliability of the stretchable interconnections, the straight interconnections on the flexible islands and the transitions between the stretchable and non-stretchable parts is improved. This approach results in a significant increase of the lifetime of the stretchable interconnections as it is doubled. In this contribution, the different process steps and materials of the technology will be highlighted. Initial reliability results will be discussed and the realization of some functional demonstrators containing a whole range of different components will further illustrate the feasibility of this technology. The advantages and disadvantages in terms of processability, cost and mechanical strength of the photo-definable polyimide will be covered.

Stretchable and washable electronics for embedding in textiles

Electronics in “wearable systems” or “smart textiles” are nowadays mainly realized on traditional interconnection substrates, like rigid Printed Circuit Boards (PCB) or mechanically flexible substrates. The electronic modules are detachable to allow cleaning and washing of the textile. In order to achieve a higher degree of integration and user comfort, IMEC-UGent/CMST developed a technology for flexible and stretchable electronic circuits. The electronic system is completely embedded in an elastomer material like PDMS (silicone), resulting in soft and stretchable electronic modules. The technology uses standard packaged components (IC’s) and meander shaped copper tracks, so that stretchable systems with complex functionality can be achieved. Testing methods for washability were selected and developed. First tests are showing promising results, leveling the path to washable electronics in textiles. In order to show the possibilities of the technology in the field of textile applications a 7x8 single color stretchable LED-matrix was designed and integrated in textile. This LED-matrix can be applied for example in wearable signage applications.