Delamination Behavior of Highly Stretchable Soft Islands Multi-Layer Materials

Stretchable electronics rely on sophisticated structural designs to allow brittle metallic conductors to adapt to curved or moving substrates. Patterns of soft islands and stable cracks in layered silver-PDMS composites provide exceptional stretchability by means of strain localization as the cracks open and the islands strain. To investigate the reliability and potential failure modes, we study the initiation and propagation of delamination in dependence of structure geometry and quality of the metal-polymer bonding. Our numerical experiments show a well-bonded metal film to be under no risk of delamination. Even weakly bonded metal films sustain moderate strains well above the limits of classical electronic materials before the onset of delamination in the soft islands structures. If delamination occurs, it does so in predictable patterns that retain functionality over a remarkable strain range in the double-digit percent range before failure, thus, providing safety margins in applications.