Fabrication of flexible carbon heaters and silver interdigitated electrodes using ink-jet printing technology for electro-chemical gas sensor applications

Purpose The purpose of this paper is to deal with an identification of a novel ink-jet printing sensor fabrication technology for fabricating flexible carbon heaters of macro and micro sizes, carbon interdigitated (IDT) electrodes and silver IDT electrodes. The technology involved in the proposed ink-jet printing method and materials used for the formulation of homemade nano-conductive inks (digital inks) are discussed in detail. The ink-jet printed flexible carbon heaters of different sizes (macro and micro) and carbon IDT electrodes and flexible silver IDT electrodes can be used as the flexible sensing layers in electrochemical gas sensors for sensitive and selective gas sensing applications. The characterization of ink-jet printed carbon heaters on Kapton substrate and its results are discussed. Similarly, the results of formulation of silver nano-conductive ink and printing of silver IDT electrodes on Kapton and its characterization are reported here for the first time. Design/methodology/approach Flexible carbon heaters of different sizes (macro and micro), carbon micro-IDT electrodes and silver IDT electrodes patterns were developed using AutoCAD 2D and printed on the Kapton (polyimide sheet) flexible substrate using the home-made nano-conductive inks with the help of EpsonT60 commercial piezo-head-based drop-on demand technology printer with standard printing options. Findings The proposed novel method is able to print heater patterns and IDT electrode patterns of approximately 12 µm and approximately 1 µm thickness, respectively, on flexible substrate using the home-made nano-conductive inks of carbon and silver by using a commercial low-cost printer. The home-made nano-conductive inks can be re-used for multiple prints up to six months shelf life. The resistance of the carbon heater was measured as 88 O under normal atmospheric condition. The novel flexible carbon heater was tested for its functionality and found to be satisfactory. The resistance of the silver IDT flexible electrodes was measured as 9.5 O which is better than the earlier works carried out in this paper. Research limitations/implications The main challenge is associated with cleaning of printing ink ejection system in the existing commercial printers. The customization of the existing printer in the near future can minimize the printing challenges. Practical implications The novel ink-jet printing technology proposed in this work is cost-effective, capable of achieving bulk production of flexible sensor elements, and consumes the least device fabrication time and high material yielding. The printing can be done with commercial piezo-head-based ink-jet printers with custom-prepared nano-conductive inks. There is a huge market potential for this paper. Originality/value Both the carbon heaters and silver IDT electrodes were printed on Kapton flexible substrate by using the commercial printer for the first time. The paper is promising the revolution in flexible low-cost sensor fabrication for mass production, and it is an alternate for thin film and thick sensor fabrication methods. The future of sensor fabrication technology will be the ink-jet printing method. In this paper, the research developments of flexible carbon heaters and flexible silver IDT electrodes for the time are reported. The characterization of carbon heaters and silver IDT electrodes were carried out and confirmed that the results are favourable for gas sensor applications.