High-Power Aqueous Zinc-Ion Batteries for Customized Electronic Devices.

Wireless electronic devices require small, rechargeable batteries that can be rapidly designed and fabricated in customized form factors for shape conformable integration. Here, we demonstrate an integrated design and manufacturing method for aqueous zinc-ion batteries composed of polyaniline (PANI)-coated carbon fiber (PANI/CF) cathodes, laser micromachined zinc (Zn) anodes, and porous separators that are packaged within three-dimensional printed geometries, including rectangular, cylindrical, H-, and ring-shapes. The PANI/CF cathode possesses high surface area and conductivity giving rise to high rate (∼600 C) performance. Due to outstanding stability of Zn-PANI batteries against oxygen and moisture, they exhibit long cycling stability in an aqueous electrolyte solution. As exemplar, we demonstrated rechargeable battery packs with tunable voltage and capacity using stacked electrodes that are integrated with electronic components in customized wearable devices.

3D Printing of Customized Li-Ion Batteries with Thick Electrodes.

The growing demand for rechargeable lithium-ion batteries (LIBs) with higher capacity in customized geometries underscores the need for new battery materials, architectures, and assembly strategies. Here, the design, fabrication, and electrochemical performance of fully 3D printed LIBs composed of thick semisolid electrodes that exhibit high areal capacity are reported. Specifically, semisolid cathode and anode inks, as well as UV curable packaging and separator inks for direct writing of LIBs in arbitrary geometries are created. These fully 3D printed and packaged LIBs, which are encased between two glassy carbon current collectors, deliver an areal capacity of 4.45 mAh cm-2 at a current density of 0.14 mA cm-2 , which is equivalent to 17.3 Ah L-1 . The ability to produce high-performance LIBs in customized form factors opens new avenues for integrating batteries directly within 3D printed objects.

Correction: 3D polymer objects with electronic components interconnected via conformally printed electrodes.

Correction for '3D polymer objects with electronic components interconnected via conformally printed electrodes' by Yejin Jo, et al., Nanoscale, 2017, 9, 14798-14803.

3D polymer objects with electronic components interconnected via conformally printed electrodes.

We report the fabrication of 3D polymer objects that contain electrical components interconnected by conductive silver/carbon nanotube inks printed conformally onto their surfaces and through vertical vias. Electrical components are placed within internal cavities and recessed surfaces of polymer objects produced by stereolithography. Conformally printed electrodes that interconnect each electrical component exhibit a conductivity of ∼2 × 104 S cm-1 upon annealing at temperatures below 100 °C. Multiple 3D objects were created to demonstrate this hybrid additive manufacturing approach, including those with an embedded circuit operated by an air-suspended switch and a 3D circuit board composed of microcontroller unit, resistor, battery, light-emitting diode and sensor.

Wettability Contrast Gravure Printing.

Silicon gravure patterns are engineered to have cells that are wettable and lands that are not wettable by aqueous inks. This strategy allows excess ink on the lands to be removed without using a doctor blade. Using an aqueous silica ink, continuous lines as narrow as 1.2 µm with 1.5 µm space are gravure printed.

Screen Printing of Highly Loaded Silver Inks on Plastic Substrates Using Silicon Stencils.

Screen printing is a potential technique for mass-production of printed electronics; however, improvement in printing resolution is needed for high integration and performance. In this study, screen printing of highly loaded silver ink (77 wt %) on polyimide films is studied using fine-scale silicon stencils with openings ranging from 5 to 50 µm wide. This approach enables printing of high-resolution silver lines with widths as small as 22 µm. The printed silver lines on polyimide exhibit good electrical properties with a resistivity of 5.5×10(-6) Ω cm and excellent bending tolerance for bending radii greater than 5 mm (tensile strains less than 0.75%).

3D printing of interdigitated Li-ion microbattery architectures.

3D interdigitated microbattery architectures (3D-IMA) are fabricated by printing concentrated lithium oxide-based inks. The microbatteries are composed of interdigitated, high-aspect ratio cathode and anode structures. Our 3D-IMA, which exhibit high areal energy and power densities, may find potential application in autonomously powered microdevices.

Transparent conductive grids via direct writing of silver nanoparticle inks.

Transparent conductive grids are patterned by direct writing of concentrated silver nanoparticle inks. This maskless, etch-free patterning approach is used to produce well-defined, two-dimensional periodic arrays composed of conductive features with center-to-center separation distances of up to 400 µm and an optical transmittance as high as 94.1%.

Planar and three-dimensional printing of conductive inks.

Printed electronics rely on low-cost, large-area fabrication routes to create flexible or multidimensional electronic, optoelectronic, and biomedical devices. In this paper, we focus on one- (1D), two- (2D), and three-dimensional (3D) printing of conductive metallic inks in the form of flexible, stretchable, and spanning microelectrodes. Direct-write assembly is a 1-to-3D printing technique that enables the fabrication of features ranging from simple lines to complex structures by the deposition of concentrated inks through fine nozzles (~0.1 - 250 µm). This printing method consists of a computer-controlled 3-axis translation stage, an ink reservoir and nozzle, and 10x telescopic lens for visualization. Unlike inkjet printing, a droplet-based process, direct-write assembly involves the extrusion of ink filaments either in- or out-of-plane. The printed filaments typically conform to the nozzle size. Hence, microscale features (< 1 µm) can be patterned and assembled into larger arrays and multidimensional architectures. In this paper, we first synthesize a highly concentrated silver nanoparticle ink for planar and 3D printing via direct-write assembly. Next, a standard protocol for printing microelectrodes in multidimensional motifs is demonstrated. Finally, applications of printed microelectrodes for electrically small antennas, solar cells, and light-emitting diodes are highlighted.

Direct-write assembly of microperiodic planar and spanning ITO microelectrodes.

Printed Sn-doped In(2)O(3) (ITO) microelectrodes are fabricated by direct-write assembly of sol-gel inks with varying concentration. This maskless, non-lithographic approach provides a facile route to patterning transparent conductive features in planar arrays and spanning architectures.

Two- and three-dimensional folding of thin film single-crystalline silicon for photovoltaic power applications.

Fabrication of 3D electronic structures in the micrometer-to-millimeter range is extremely challenging due to the inherently 2D nature of most conventional wafer-based fabrication methods. Self-assembly, and the related method of self-folding of planar patterned membranes, provide a promising means to solve this problem. Here, we investigate self-assembly processes driven by wetting interactions to shape the contour of a functional, nonplanar photovoltaic (PV) device. A mechanics model based on the theory of thin plates is developed to identify the critical conditions for self-folding of different 2D geometrical shapes. This strategy is demonstrated for specifically designed millimeter-scale silicon objects, which are self-assembled into spherical, and other 3D shapes and integrated into fully functional light-trapping PV devices. The resulting 3D devices offer a promising way to efficiently harvest solar energy in thin cells using concentrator microarrays that function without active light tracking systems.

Ultrathin silicon solar microcells for semitransparent, mechanically flexible and microconcentrator module designs.

The high natural abundance of silicon, together with its excellent reliability and good efficiency in solar cells, suggest its continued use in production of solar energy, on massive scales, for the foreseeable future. Although organics, nanocrystals, nanowires and other new materials hold significant promise, many opportunities continue to exist for research into unconventional means of exploiting silicon in advanced photovoltaic systems. Here, we describe modules that use large-scale arrays of silicon solar microcells created from bulk wafers and integrated in diverse spatial layouts on foreign substrates by transfer printing. The resulting devices can offer useful features, including high degrees of mechanical flexibility, user-definable transparency and ultrathin-form-factor microconcentrator designs. Detailed studies of the processes for creating and manipulating such microcells, together with theoretical and experimental investigations of the electrical, mechanical and optical characteristics of several types of module that incorporate them, illuminate the key aspects.

Wet-chemical synthesis of crystalline BaTiO3 from stable chelated titanium complex: formation mechanism and dispersibility in organic solvents.

Crystalline barium titanate nanoparticles were synthesized in solution at low temperature (70 degrees C) from acetylacetone chelated titanium complex and barium hydroxide. Very fine crystalline solids were characterized to cubic phase of BaTiO(3) by X-ray diffraction studies of the air-dried samples. It was observed that the crystalline barium titanate was formed in solution at Ba/Ti molar ratio > or =2.5. The dependence of the reaction temperature and the Ba(OH)(2) concentration (in terms of Ba/Ti molar ratio) on formation of crystalline BaTiO(3) in solution-phase was studied, and a plausible mechanism toward the formation of crystalline BaTiO(3) was also proposed. Crystallite sizes of the BaTiO(3) were found to be in the range 33-50 nm, while the average particle sizes, measured by dynamic light scattering method were in the range 70-100 nm. The crystalline BaTiO(3) prepared from acetylacetone chelated titanium complex was highly dispersible in organic medium such as N-methyl-2-pyrillidone (NMP) and N,N-dimethyl formamide (DMF).

Core/shell silica-based in-situ microencapsulation: a self-templating method.

Core/shell SiO2 and (RSiO1.5)(1-x)-(SiO2)x (R = alkyl) microcapsules were synthesized via a single-step O/W emulsion system using a self-templating method; the facile synthetic process provides an in-situ encapsulation route for a wide range of lipophilic functional compounds.

Redispersible rutile TiO2 nanocrystals in organic media by surface chemical modification with an inorganic barium hydroxide.

The present paper describes the synthesis of the redispersible rutile TiO2 nanocrystals in organic media by surface chemical modification reaction in an aqueous barium hydroxide solution. In our facile surface modification reactions, the surfaces of the TiO2 nanocrystals are coated by bimetallic TiOBa spices and saturated with BaOH terminal groups. The inherent characteristics such as morphology, size, crystallinity, and color of the nanocrystals remained almost unchanged after surface-treatment, but their dispersibility in organic media such as methanol and DMF were remarkably enhanced. It is ascribed that BaOH groups in the surface of the TiO2 nanocrystals prevented the formation of covalently bound agglomerates through Ti-O-Ti condensation reaction among the nanocrystals during the purification and water-elimination procedures.