Lateral-crack-free, buckled, inkjet-printed silver electrodes on highly pre-stretched elastomeric substrates

We report the formation of lateral-crack-free silver electrodes on highly pre-stretched poly(dimethylsiloxane) (PDMS) substrates using the inkjet-printing method followed by an annealing process under the pre-stretched state. Due to Poisson's effect, cracks are easily obtained in the direction lateral to the pre-stretching and releasing directions when the highly pre-stretched substrate is released after the electrode formation. In our method, however, Poisson's effect is suppressed significantly from the PDMS thermal expansion perpendicular to the pre-stretched direction during the annealing process. In order to prevent the formation of a lateral crack, the annealing temperature needs to be optimized for each pre-stretching condition. We modelled their relationship using Poisson's ratios and thermal expansion coefficients of the substrate and silver materials. Our measurement results showed consistent result with the simulation. The resistance of the fabricated silver electrodes negligibly changes under up to 17% strain and even after 1000 time stretching cycle tests.