stretchable electronics for smart textiles -...
TRANSCRIPT
Stretchable Electronics for
Smart Textiles
J. Vanfleteren
IMEC – UGent/CMST Technology Park Building 914-A,
B-9052 Gent-Zwijnaarde, BELGIUM http://tfcg.elis.ugent.be/ or http://www.cmst.be/
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Introduction
• Wearable and implantable systems require lightweight, comfortable, conformable versions of electronics and sensor systems conventional large
rigid PCB’s are not acceptable
(Philips)
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Introduction
2 facts to take into account for development of wearable and implantable circuits :
• Fact #1 : In industrial environment : electronic circuits are produced and assembled on flat substrates (rigid or flex)
• Fact #2 : Demand for complex systems requires the use of COTS (components-off-the-shelf) like commercial IC’s : microcontrollers, memory, display drivers, radio chips, etc.
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Introduction – options for comfortable electronics
Option#1 : Small area flat substrates
Requires :
• Miniaturisation & high density integration
• Use of 3rd dimension of the substrate (multilayer, embedded & stacked components, folded flex)
• Possible embedding in 3D shaped biocompatible material
(Oticon)
Implantable pressure sensor
Together with KULeuven
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Introduction – options for comfortable electronics
Option#2 : non-flat substrates
Case#2a : application allows/requires compact, non-flat assemblies : • from flat to cylindrical or conical shape : possible to use flexible circuits • 3D integration for surface minimization
T. Torfs, FS2, App. Sess. 3
UTCP
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Introduction – options for comfortable electronics
Option#2 : non-flat substrates
Case#2a : application allows/requires compact, non-flat assemblies :
• from flat to any other shape (e.g. spherical : stretchable circuits necessary; e.g. spherical camera sensor, (J. Rogers group, Beckman Institute, U. Illinois)
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Introduction – options for comfortable electronics
Option#2 : non-flat substrates
Case#2b : application requires large area, distributed electronics, e.g. displays & signage, sensor arrays
• at least flex cylindrical or conical shape
• preferably stretchable circuit arbitrary shape
Stretchable circuit = (compact) rigid/flex functional islands with stretchable interconnects
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Introduction – options for comfortable electronics
Small area
Flex
Stretch
Large area
Flex
Stretch
Non-flat substrates
Flat substrates : small area
Unobtrusive circuits
(Use as functional islands in stretchable circuits)
UTCP SMI
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Stretchable electronics
• Start from conventionally packaged sensors and electronic components, not available in flexible / elastic format circuits with advanced functionality possible
• Individual components or rigid/flexible component islands connected by stretchable wiring
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• Conductive polymers : conductivity 3 orders of magnitude lower than metallic conductors – Intrinsic conductive polymers (PEDOT, PANI, Polypyrrole,…) – Stretchable insulating polymers with conductive fillers (e.g. Ag
filled silicones)
• Nanotechnology based materials : e.g. Metal Rubber™ of Nanosonic Inc. (www.nanosonic.com) : – Self-assembled nanocomposite material – Electrical resistance 5x10-6 Ω·cm
(Cu : 1.7 x 10-6 Ω·cm) – Max. elongation : 200% – Still extremely expensive
• Metallic conductors – Highest conductivity – Lowest cost – Standard use in PCB industry
Introduction - Stretchable wiring options
Our choice
But : metals not intrinsically stretchable ??
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Stretchable wiring – out of plane deformation of
metal interconnects
• Deposition of Cr/Au conductors on pre-stretched Silicone
(S. Lacour, Princeton University, New Jersey, USA)
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• Lacour et al. (Princeton), IEEE Proceedings, August 2005)
•
Stretchable wiring – out of plane deformation of
metal interconnects
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• Stretchability, while maintaining sufficient conductivity, obtained by meander-shaped fine-line metallic conductors - “2D springs”
• Mechanical Modelling : Stress under deformation (stretching) dependent on : – Wave shape (moderate) – Wave amplitude
(moderate) – Line width (drastic)
2D metallic springs – in plane deformation of
metallic interconnects
“multitrack” “horseshoe” shaped conductors
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Overmoulding of pattern
plated Au tortuous wires
(Source : D. Gray et al.,
Johns Hopkins University,
Baltimore, MD, USA)
expensive process (evaporated silver sacrificial layer, batch processing (no reel-to-reel capabilities)
“MID” = Moulded
Interconnection
Device
2D metallic springs – in plane deformation of
metallic interconnects
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CMST’s MID based processes overview
Technology ID Name
SMI-1 Plated conductor technology
SMI-2 Peelable substrate technology
SMI-3 Laser structured conductor technology
SCB-1 Stretchable substrate technology
Acronym Full Name Properties
SMI Stretchable Mould Interconnect
Circuit fabrication and component
assembly on sacrificial flex or rigid
substrate; stretchability introduced at
the end of the process
SCB Stretchable Copper Board
Start from elastic substrate;
circuit fabrication and component
assembly on this substrate
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CMST’s MID (Mould Interconnect Device) processes
overview
Common technology properties :
• Key features : – Meander shaped interconnections
– Moulding technology
– Stress relief (rigid/flex/stretch transistions)
• Processes close to industrial printed circuit manufacturing use conventional leadfree solder
assembly process (250-260 degC)
• Completely embedded circuits – Washability
– Implantability
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• (a) pattern plating of meander shaped metal wiring on metallic sacrificial substrate (e.g. Au plating on Cu foil)
• (b) mount components
• (c) mold/cast stretchable substrate material (silicone / poly-urethane)
• (d) remove sacrificial substrate (wet etch)
• (e) optionally mount additional components
• (f) apply second layer of stretchable material for complete embedding
SMI-1 : plated conductor technology
components
Underfill, adhesive Local stiffener
(a)
(b)
(c)
(d)
(e)
(f)
(a)
(b)
(c)
(d)
(e)
(f)
Elastic carrier
Flexible base material Meander shaped wiring
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• All processing (including component assembly (b)) is done on non-stretchable substrate, similar to flex assembly
• completely embedded circuits possible (immersion in liquids, implantation)
• potential to produce non-planar (e.g. cylindric) circuits (by bending Cu foil + components before moulding)
• Process applicable for
• Any platable metal stack (Au, Ni/Cu/Ni/Au, Pt,..)
• Any liquid, curable stretchable materials (silicones (Dow Corning), polyurethanes,...)
• Back-etch of Cu sheet not environmentally friendly
components
Underfill, adhesive Local stiffener
(a)
(b)
(c)
(d)
(e)
(f)
(a)
(b)
(c)
(d)
(e)
(f)
Elastic carrier
Flexible base material Meander shaped wiring
SMI-1 : plated conductor technology
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Casting
Moulding
Sylgard 186
Stretchable materials selection
• Suppliers of silicone materials : DOW Corning, Nusil
• From stretchability point of view : Sylgard and Silastic are the most interesting DOW Corning materials
2703,060’ @150°CBLACK
Store @ -20°C1PrintingJCR6224
0,13707,4WL-5351
0,4516037,6Low-
temperature-
curable
Photopatternable
Store @ -15°C1Spinning
WL-5150
* Dowcorning
360 medical fluid
=>lower
viscosity
60470 15’ @100°C
Designed for
MEDICAL
device
encapsulation
Silastic
MDX-4210
3,91,916015’ @150°C
Used in literature
as a stretchable
dielectric2
base/curing agent
10:1
Spinning
Sylgard 184
Extra
products
needed
Viscosity
(Pa.s)
Young’s
Modulus
(MPa)
Elongation
(%)
CureRemarks# componentsWay of
application
Dowcorning
type
2703,060’ @150°CBLACK
Store @ -20°C1PrintingJCR6224
0,13707,4WL-5351
0,4516037,6Low-
temperature-
curable
Photopatternable
Store @ -15°C1Spinning
WL-5150
* Dowcorning
360 medical fluid
=>lower
viscosity
60470 15’ @100°C
Designed for
MEDICAL
device
encapsulation
Silastic
MDX-4210
3,91,916015’ @150°C
Used in literature
as a stretchable
dielectric2
base/curing agent
10:1
Spinning
Sylgard 184
Extra
products
needed
Viscosity
(Pa.s)
Young’s
Modulus
(MPa)
Elongation
(%)
CureRemarks# componentsWay of
application
Dowcorning
type
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a) Injection of polymer to embed the first face
of system on cupper foil
b) Etching of the cupper substrate
c) Injection of the bottom layer of polymer
d) Unmolding the stretchable system
a
b
c
d
Moulding technology for polymer substrates
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Mould Design
The areas where the
components are, are
thicker to make them
locally less
stretchable.
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Use of solder mask for component assembly
• component assembly compatible / identical to standard flex circuit assembly
• low level stress at component assembly sites
0,5 mm
Component
Solder or ICA
Solder Mask (not removed)
Plated stretchable
interconnectionSilicone
1,5 mm
0,5 mm
Component
Solder or ICA
Solder Mask (not removed)
Plated stretchable
interconnectionSilicone
1,5 mmComponent
Solder or ICA
Solder Mask (not removed)
Plated stretchable
interconnectionSilicone
1,5 mm
8 lead SMD packaged temperature sensor assembled using adhesives and embedded in
PDMS (Dow Corning Silastic)
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Operating blue LED under 35%
stretching
Stretch test of operating elastic
circuit
SMI-1 Demonstrators
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Stretchable thermometer
Real-time temperature measurement
SMI-1 Demonstrators
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Drawbacks of SMI-1 :
• Etching of (thick) uniform Cu sacrificial substrate
• Shorts between component pads when mounting components : – Impossible to assemble charged battery
– Impossible to check circuit functionality and to perform repair
SMI-1 : plated conductor technology
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SMI-2 : Peelable Substrate Technology
• Elimination of conducting sacrificial substrate : use polyimide (PI) flex or FR4 type carrier subsrate instead of metal foil
• No more plating of the conductors standard PCB Cu
• Process close to PCB manufacturing and component assembly practices (use of lead-free solder)
• Need for high-T temporary bonding adhesive (withstanding 250degC solder process)
Lamination
Lithography + wet etch
Embedding I
Peeling
Embedding II
Assembly
copper
wax
carrier
PDMS, PU component
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SMI-2 demonstrators
• Inductive link (with KULeuven/ESAT/MICAS)
• 70micron Cu to ensure sufficient high Q-factor
• Water-proof operation (> 2 months)
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Standard flex
PI + Cu
Laser cutting
Assembly +
Molding I
Molding II
Removal of
residues
copper
PI
wax
ceramic
silicone
component
• Very fast prototyping technology
• Cu on polyimide carrier high
reliability
• Industrialization of residue removal step ? Seems difficult
SMI-3 : Laser structured conductor technology
After laser cutting After residue removal
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SMI-3 demonstrators
Stretchable watch (master thesis T. Vervust)
• Normally processed single-sided flex with laser cut stretchable interconnects
• Fully functional stretchable wrist watch inlcuding
• TI Microcontroller
• Rigid 4 x 7 segment TN LCD
• Pushbuttons
• Battery
• Passive components
• Lifetime : 1 year (battery)
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SMI-3 demonstrators
2nd Approach :
• “perforated flex” : “stretchabilisation” of standard flexible circuit
• No real stretchable interconnects
• Less deformable, more reliable than 1st approach
• 7 x 8 LED matrix, driven by single chip
(charlieplexing)
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SCB-1 : Stretchable substrate technology
copper
photoresist Silicone
component
• Rough copper base substrate (18 μm thick) (a)
• Spinning silicone (as thin as few 10s of microns) (b)
• Patterning the Cu (c)(d)
• Component assembly (now on stretchable substrate) (e)
• Conventional PCB manufacturing and component assembly flow
• use of high T stretchable material necessary to allow use of vapour phase reflow and SAC solder (260° C max.) for component assembly
(a)
(b)
(c)
(d)
(e)
(f)
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Copper TW-TW
Spinned silicone Polyimide foil (no adhesion to cured silicone)
Patterned meanders and functional island in copper (Ni/Au plating)
Soldered components Final system
SCB-1 demonstrators
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Comparison of the process flows
Technology Name
Lab
throughput
speed
Potential indutrial
throughput speed
Conductor
thickness
(micron)
Min. conductor
pitch (micron)
SMI-1Plated conductor
technologyslow (plating) slow (plating) 4 to 7 30
SMI-2Peelable substrate
technologyfast fast 17, 35, 70 100
SMI-3Laser structured
conductor technologyvery fast
slow (laser
structuring)9, 12, 17, 35… 50
SCB-1Stretchable substrate
technologyfast fast 17, 35, 70 100
Technology Name
Potential
indutrial
throughput
speed
Test before
embedding
Rework before
embedding
Rework after
embedding
SMI-1Plated conductor
technologyslow (plating) not possible not possible not possible
SMI-2Peelable substrate
technologyfast possible possible not possible
SMI-3Laser structured
conductor technology
slow (laser
structuring)possible possible not possible
SCB-1Stretchable substrate
technologyfast possible
possible, but
more difficultnot possible
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Comparison of the process flows (2)
Technology Name Special features / issues
SMI-1Plated conductor
technology
very fine pitch possible
battery integration difficult
lots of waste (Cu substrate back-etch)
SMI-2Peelable substrate
technology
need for high-T temporary bonding adhesive to avoid
process instability during solder assembly
SMI-3Laser structured
conductor technologyCu meanders still on PI carrier; high reliability expected
SCB-1Stretchable substrate
technologylimited to high-T elastic carrier materials
Favourite technology, in terms of the state of technology development and potential industrialisation :
SMI-2 : Peelable substrate technology (SMI-3 (“perforated flex”) also used for fast prototyping)
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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2 types of « stretchability » tests :
• 1-time stretchability (stretch until failure, i.e. loss of electrical connection)
• Cyclic stretching (more relevant for actual use)
Relevant cases :
• Reliability of stretchable interconnects
• Reliability of transition component / component island to stretchable interconnect
Measurements
• Electrical resistance
Reliability tests : uniaxial stretching
Reliability test vehicle (with or without interposer)
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R = 900 µm
SMI-3 technology
W <= R/10
H = 0 => H0
H = 30deg => H30
H = 45deg => H45
3 type of “horseshoes” :
1-time stretchability
0
3
L : track
period
W : track
width
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Reliability tests : Cyclic uniaxial stretching
Elo
ngation
Time 10s
20%
cycle
Ω
Instron 5543
• 3000 cycles until conductor break for – SMI-3 technology (laser cut Cu on PI)
– Track width W = 100µm
– Meander length L = 800µm
– Horseshoe angle = 30
– 20% elongation
• SMI-2 (pure Cu) behave worse
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• Cyclic uniaxial stretch tests on SMI-2 samples • Meander radius = 700m, metal track width = 100m • Period of stretch & release cycle = 2s • Monitoring of electrical continuity of stretchable interconnection lines
Reliability tests : Cyclic uniaxial stretching
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Measurements
SMI-3 (Cu on PI) Ag filled PDMS shunt
End of life
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y = 2E+06x-3.061
100
1000
10000
100000
1000000
1 10 100
Inte
rco
nn
ect lif
etim
e (
# c
ycle
s)
% strain
Lifetime of a stretchable interconnect
Ongoing experiment
• Lifetime decreases with % strain to the power 3 • At 10% strain : lifetime of 2500 cycles • At 2.5% : 500 000 cycles exceeded, test still ongoing • At lower strains (< 5%) : lifetime exceeds this law
Reliability tests : Cyclic uniaxial stretching
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1) Crack formation and propagation
avoid plastic deformation
by use of other metals
optimize meander design,
based on FEM modeling
reduce crack propagation
with PI support
2) Buckling :
reduce width of meander track (planned)
Support meander with PI
Reliability : failure modes and solutions
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Reliability enhancement : Multitrack design
“Twirl” shape
Reliability enhancement by providing bridges
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20% deformation 60% deformation
Non-lethal break
Reliability enhancement : Multitrack design
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Straight tracks on component island: when stretched, a lot of stress is induced in the copper wiring, which breaks. Components on pads of stretch interconnects: when stretched, a lot of stress is on the solder joints and pads, which break.
Polyimide supporting the component island protecting the straight tracks and soldered joints
Polyimide supporting the stretchable copper conductors
metal
metal
B
support
support
metal
Reliability enhancement : component and
meander support for SMI-2
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Standard
PCB
process
Temporary support
during process
Temporary adhesive
during process.
Melts when heated.
Strong and flexible
Polymer
Flexible support
for functional
Islands and
meanders
Reliability enhancement : component and
meander support for SMI-2
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Flexible functional
island
Stretchable
interconnection
Rigid carrier Wax Adhesive layer
Reliability enhancement : component and
meander support for SMI-2
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Completely embedded
in stretchable material
Reliability enhancement : component and
meander support for SMI-2
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– Flexible supporting islands:
– Better transition between rigid interposers
and stretch connections
– Better transition between SMD components
and stretch connections
– Better transition from flex to stretch:
patterning supporting polyimide and copper
– Stretchable conductors:
– Support of stretchable conductors by
polyimide
Reliability enhancement : rigid-flex-stretch
transition improvements
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– Molding improvement:
– Gradual transition (fillet) between thicker and thinner parts
Less local stress concentration at interface
Reliability enhancement : rigid-flex-stretch
transition improvements
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Interposer integrated Rigid-flex-stretch transition
Molding improved Single layer:
multilayer interposer can be mounted
Reliability enhancement : rigid-flex-stretch
transition improvements
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4 samples TM1-v1 5 samples TM1-v2
• cyclic strain of
10% @ 1% strain
rate
• supported
component islands
• non-supported
meanders
# Cycles to failure
Large spread
Reliability enhancement : rigid-flex-stretch
transition improvements
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Failure modes : Meanders (m):
Interposer connection: - Base (B): - Thin buckle (T) - Wide buckle (W)
M T W B
Position on crossection:
• Failure mechanisms : breaking of supporting PI layer, Cu plastic
deformation
• Combination meander narrowing / thickness transition to be
optimised
Reliability enhancement : rigid-flex-stretch
transition improvements
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Polyimide as mechanical meander support
Photodefinable polyimide significantly improves lifetime
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Thin-film based SMI with double-sided PI meander
support
Cyclic strain : 10%
Strain rate : 10%/s
Lifetime > 500’000 cycles (4 tracks, 2 with PI and 50nm TiW/200nm Au same pattern, 2 with wider PI support)
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Meander circuit design
• Meanders designed as “horseshoes” = connected circular segments
• Best stress distribution along the line
• Theoretical stretchability determined by α
Theoretical stretchability
in meander direction
Theoretical stretchability
perpendicular to meander
direction
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Meander circuit design
Preliminary design rules :
• W/R < 0.1
• Practical stretchability 0.1*theoretical stretchability (H=0…45deg)
• W : determined by technology, determines also minimum R
• Application determines required practical stretchability, this determines horseshoe angle
L : track
period
W : track
width
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Interconnection: Principle
Stretchable test sample
with interconnection pads
Copper pad, free of silicone
Interconnect different stretchable modules
with: stitched conductor, embroidered wire,
conductive ribbon,…
Textile integration
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Textile integration: procedure
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Textile integration: Screenprinting PDMS gluing layer
9601
Viscosity (centipoise)
9600
186
280000
490000
66700
4575 184
Screenprinting done @ Centexbel
PDMS type Dow Corning 9600 textile glue
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Lamination of silicone sheet (186) on textile via silicone layer of 9601
No silicone on backside
Viscosity
(centipoise)
186
9601
66700
280000
Silicone
Textile integration: Screenprinting PDMS gluing layer
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7x8 led matrix on a T-shirt
Textile integration: Demonstrators
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Molding allows creation of breathable zones (textile integration)
Technology extensions – textile integration
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Stitched conductive yarn : Shieldex (PA + Ag)
Stitched contactpad
Sealed with silicone
(Mechanical and water
protection)
Stitched conductive yarn (done @ Centexbel Verviers)
Textile integration: Interconnection
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Sealed with silicone
Soldered electric wire
Electric wires
Soldered
Textile integration: Interconnection
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Soldering + sealing
Textile integration: Interconnection
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Finished samples
Textile integration: Interconnection
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Textile integration : washability
Complete
embedding creates
potential for
washability
JL-73
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- On flexible substrate (lasercut) - Daisy chain of 0 Ohm resistors: 0603 and 0402 package - Dummy IC’s with daisy chain: TSSOP 28 and QFN 32 - Contact pads P1 to P43 to detect broken contacts in the chain - Contact pads are accessible for measurement trough openings in silicone
10cm
Purpose: Reliability of solder contacts of SMD components on flexible islands Mechanical test: washing
Textile integration : washability
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JL-74
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Sample details: package types & measurement points
FR4 stiffeners underneath TSSOP and QFN
components
Reference sample Optimized sample
Textile integration : washability
74
JL-75
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Testsamples and test overview
=
For every test, 6 samples (5 optimized + 1 reference sample) Test effect of using protective bag during washing
Test reproducability of results
Textile integration : washability
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JL-76
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1) Chain status after 25 cycles (woven, in bag) – reference sample:
2) Chain status after 25 cycles (woven, no bag) – reference sample:
Textile integration : washability
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JL-77
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Crack in solder & copper Delamination
Failure on TSSOP leads
Failure analysis of reference sample:
Textile integration : washability
JL-78
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1) Chain status after 25 cycles (woven, in bag) - Optimized design:
Textile integration : washability
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JL-79
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1) Woven, in bag
2) Woven, no bag
-
Both for optimized design Better with protective bag !
Textile integration : washability
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JL-80
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1) Woven, in bag
3) Woven, in bag
Reproducible
Both for optimized design
Textile integration : washability
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JL-81
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Cracks in flex of resistor chains
Failure analysis of optimized design:
Folding of flex (dummy IC islands)
Corners of flex sticking out of PDMS encapsulation
- Partner restricted PTW OCT. 2011 - HUMAN++
Textile integration : washability
81
JL-82
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1) Chain status after 25 cycles (knitted, in bag) - Optimized design:
Textile integration : washability
No failures after 25 washing cycles !
No measurements at t=0 early failures might be
due to assembly
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JL-83
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1) Chain status after 25 cycles (knitted, not in bag) - Optimized design:
Textile integration : washability
No failures after 25 washing cycles !
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Stretchable electronics applications
Stretchable electronics useful only if
• Application requires large surface with electronic components or modules, distributed over the area
or
• Circuit is too large and must be partitioned in single flex/rigid modules which are then connected with stretchable interconnects
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Stretchable electronics applications
Examples :
• Lighting, and especially LEDs – Wearable signage : leisure (party shirt), safety (signage in jackets for
road workers, bikers,…), advertising (the modern sandwich man),
– advanced lighting : atmospheric lighting in interior (upholstery, curtains, walls, etc.)
• Large area arrays with distributed sensors – Pressure sensors in mattress
• Body area sensor networks, and especially movement sensors – Fall detection
– orientation tracking, body posture tracking for : gaming & entertainment (advanced Wii), music & dance performances, revalidation, sports, medical applications (epileptic seizure detection)
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PI + copper Soldermask applied PI + copper Soldermask applied
Philips EC-STELLA demonstrator: fitness monitor
Flexible islands for interposers
Smooth
flex-stretch transition
Stretchable electronics applications
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Functional boards mounted on flexible islands
Functionality of circuit tested before molding Molded demonstrator using Sylgard 186 PDMS
Fully Functional demo, The system includes a
wireless link, a rechargeable battery circuit and
accelerometers for activity detection.
Stretchable electronics applications
Philips Activity Monitor
Developed in EU Project Stella
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Embedded in Sylgard 186 by casting
Respiration sensor connections
Buzzer connections
Temporary flex connector Polyimide
Copper
Soldermask
Flexible island
Smooth
flex-stretch transition
Smooth
flex-stretch transition Verhaert EC-STELLA demonstrator: baby monitor
Stretchable electronics applications
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SMI Demonstrators
Verhaert Baby breathing demonstrator The demonstrator contains 79 components, 2 rubbery rulers and a buzzer.
The rubbery rulers are integrated in the moulded device acting as sensors for the breathing detection.
Developed in EU Project Stella
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Party Shirt (5x10 full color led matrix)
SMI Demonstrators
Including wireless communication
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Party Shirt (5x10 full color led matrix)
SMI Demonstrators
Fully integrated in T-shirt
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Contents
• Introduction – options for comfortable electronics
• Stretchable Mould Interconnect (SMI) technologies
• Reliability / technology improvement
• Textile integration and washability
• Applications
• Conclusions and outlook
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Conclusions and outlook
94
• Stretchable circuits were developed, based on meander shaped high-conductance Cu interconnects and liquid injection moulding technology
• The technology is to a large extent compatible with standard PCB circuit fabrication and assembly technology
• The feasibility of stretchable circuitry was proven by mechanical reliability tests and functional demonstrators
• Textile integration is feasible; washability up to 25 cycles proven for test samples on knitted substrates
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• Industrialisation of the technology requires a chain of companies with various competences :
• Printed Circuit Board Manufacturers
• Electronic assembly companies
• Polymer processing specialists (moulding, …)
• Textile integrators (confection)
• End users
• Technology has reached the level of maturity to start building this chain
Conclusions and outlook
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• EC-IST-FP6-IP-”STELLA” (STretchable ELectronics for Large Area applications) (contract nr. 028026) (http://www.stella-project.eu/)
• EC-IST-FP7-CA-”Systex” (co-ordination action on intelligent textile systems (since 05/2008) (http://www.systex.org/)
• Flemish IWT-SBO-”BioFlex” : Biocompatible Flexible and Stretchable Electronics circuits (http://tfcg.elis.ugent.be/projects/bioflex/)
• Belgian TAP2-”SWEET” : Stretchable and Washable Electronics for Embedding in Textiles (http://tfcg.elis.ugent.be/projects/sweet/)
• EC-IST-FP7-IP-Place-It – “Platform for Large Area Conformable Electronics by InTegration” (since 02/10) (http://www.place-it-project.eu/)
• EC-IST-FP7-IP-PASTA – “Integrating Platform for Advanced Smart Textile Applications” (starting 10/2010)
Acknowledgements
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• J. Fjelstad et al. “Stretchable Circuits”, in “Flexible Circuit Technology”, 4th edition, BR Publishing, Seaside, USA, Chapter 13, pp. 478-513, November 2011.
• J. Vanfleteren et al., “Printed circuit board technology inspired stretchable circuits” MRS Bulletin, Vol.37, pp.254-260 , March 2012.
• T. Vervust et al., “Integration of stretchable and washable electronic modules for smart textile applications”, J. Textile Institute, 05 Mar 2012, 12 pages.
• Y.-Y. Hsu et al., "The effects of encapsulation on deformation behavior and failure mechanisms of stretchable interconnects", Thin Solid Films, Vol. 519, No. 7, pp. 2225-2234, Jan. 2011.
• R. Verplancke et al. “Thin-film stretchable electronics Technology based on meandering interconnections: fabrication and mechanical performance”, J. Micromech. Microeng., Vol.22, No1, published online December 8, 2011.
• Y.-Y. Hsu at al., “Polyimide-Enhanced Stretchable Interconnects: Design, Fabrication, and Characterization”, IEEE Trans. Electr. Dev., Vol. 58, No. 8, pp. 2680-2688, August 2011.
• Patents / patent applications : #US 7,487,587 B2 (February 10, 2009), #EP 1 746 869 B1 (July 27, 2011), #US 2009 0107704 A1 (April 30, 2009), #WO 2010/086416 A1 (August 5, 2010), #WO 2010/086033 A1 (August 5, 2010), #WO 2010/086034 A1 (August 5, 2010),
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