High-resolution maskless patterning of AgNWs based on adhesion enhancement of a printed conductive polymer

Facile high-resolution patterning of silver nanowires (AgNWs) is a key enabling technology for expanding their usage to flexible and stretchable electronics applications. Although various patterning methods have been proposed, only high-cost and complex mask-based methods have demonstrated potential micrometer-scale pattern-ability, which have no design freedom of changing patterns in a facile manner. Herein, we suggest a maskless high-resolution patterning method by combining an adhesive underlayer and inkjet-printed conductive polymer patterns. AgNWs located between them are tightly bonded and thus are resistant to a solvent-based rinsing process. AgNWs under the conductive polymer patterns remain while uncovered AgNWs are removed during the rinsing process. Our approach allows easy patterning of AgNWs on various substrates including glass, plastic, and stretchable elastomer. The excellent mechanical properties of AgNW interconnects are demonstrated in a stretchable light-emitting diode array. By introducing an electrohydrodynamic printing method, high-resolution AgNW patterns with linewidths below 20 µm are fabricated, which are used for a heater based on transparent grid AgNW electrodes. Based on our results, we believe that our method paves the way for a convenient patterning process of high-resolution electrode circuits with a high degree of freedom even on a deformable platform.