Interface is the Achilles' heel in flexible electronics, where slipping, delamination, or cracking resulting from the intrinsic mechanical property mismatch of different materials might fail the device or cause degradation. Robust connections with strong interfacial strength and low interfacial impedance are highly desired in all kinds of flexible devices, especially when they require stretchability. Here, a new strategy of employing homogeneity is proposed to facilely achieve robust connection without introducing a third-party interlayer. The key to this strategy is implementing different functions in the same component materials, and in this work, this strategy is demonstrated by exploring the uniformity of carbon nanotube (CNT) in thermoplastic polyurethane (TPU) elastomer. Tuning the uniformity of CNT in TPU elastomer, two kinds of CNT-TPU composites (CTCs) are fabricated. They present contrasting properties of conductivity (281 folds), Young's modulus (7.1 folds), and strain sensitivity (15.7 folds) with the same weight fraction of CNT (15 wt %), and thus they can respectively act as strain sensor and interconnector in all-CNT-based stretchable strain monitoring electronics. The interlocking effect caused by spontaneous entanglement of surface polymer chains and the reconstruction of percolation network at the interface during drying confer the connection with robustness. The practical value of this strategy has been exemplified by the fabrication of a robust epidermis device via additive manufacturing. This epidermis device is patterned in a fractal motif for conformal contact and can sensitively monitor body motions and radial artery pulse.
Keywords: additive manufacturing; robust interface; strain sensor; stretchable electronics.