Fabrication And Study Of 3D Conformal Electronics Based On Thermoforming

In recent years,electronic products have developed rapidly,while the requirements for it also increase.In order to closely connect people and things,electronic devices need to have good conformity and suitability.But many products in real life contain threedimensional curved surface,while the existing electronic devices are difficult to apply to curved surface due to its low stretchability and deformability.Based on the above problems,the thesis proposes a manufacturing process of threedimensional conformal electronics based on thermoforming,which mainly includes laser patterning,transfer printing,visual alignment and thermoforming.By introducing an adhesion interlayer between metal circuit and the thermoplastic film,the electronic device could conform to the three-dimensional curved surface without obvious wrinkle and delamination.In order to evaluate the effects of thermoforming,the thesis proposes three parameters including the angle of central deviation,the angle of edge warping,and the state of circuits.The influence of factors such as thickness of adhesion interlayer,heating temperature and size of metal circuits is explored.Based on the optimized experimental parameters,it is certain to obtain a device with the angle of central deviation <5°,the angle of edge warping <10°,and the circuits fully conform and attached.Then by means of grid analysis and visual recognition,the thesis establishes the polar coordinate system to determine the polar diameter and polar angle of the metal circuit,and explores the mapping relationship before and after thermoforming.The mapping relationship provides technical guidance for the electronic device to be accurately attached to the curved surface.Finally,a series of applications including connecting wires and spiral antennas are fabricated,and their performance have been verified.The manufacturing process of three-dimensional conformal electronics based on thermoforming can alleviate the detachment of the wrinkles caused by the difference in properties between metal circuit and the thermoplastic film by introducing the adhesive interlayer.And it is believed to be a potential technique for mass production,because it can effectively ensure the accuracy and repeatability of processing by means of visual alignment.Besides,it is simple,low cost and no pollution.