An
easy-to-fabricate, high-performance, and ultrabendable heater is always
essential for the development of flexible devices such as gas sensors.
Currently, most of the flexible heaters involve vacuum facilities
or special inkjet printers/inks, which leads to complex processes
and high fabrication cost. In this work, an innovative polymeric metalization
technique was developed on polyimide substrate: in addition to the
tunable electrical properties, Ag thin films obtained through the
low-temperature solution-based process, the so-called surface modification
and ion exchange (SMIE) process, could provide enhanced interfacial
adhesion and mechanical stability. With a carbon ink as a masking
layer, generated by a common home-/office-use inkjet printer, more
than 400 patterned flexible heaters can be batch-fabricated on an
A4 size polyimide conveniently. The results indicate that the heaters
exhibit good electrical properties as well as superior bending stabilities.
For the heaters with dimension of 1 cm × 1 cm, under an applied
voltage of 20 Vdc, the maximum temperature achieved is
300 °C. Both the response time and recovery time are less than
15 s. The heaters can bear more than 1200 times bending cycling with
a relative resistance change ratio of 0.11%. The developed technology
is compatible with current batch fabrication processes such as roll-to-roll
and can be employed to develop flexible heaters with high mechanical
stability in the future.