大面积柔性电子曲面共形制造及智能蒙皮应用

Flexible curved electronics hold the characteristic of large area, flexibility, light weight and non-coplanar so that they have huge development prospect and wide application in the fields of aeronautics/astronautics, information/communication, and health care. According to the requirements of large-area, heterogeneous-material and conformal manufacturing for flexible electronics such as aircraft smart skin, the interdisciplinary research will focus on "multiscale surface-conformal manufacturing for large-area flexible electronics" from the viewpoint of device design, process mechanism and equipment principle. We will propose a design method of flexible sensor network with large deformation and high stability, and a flexible surface mapping method with geometric-physical hybrid constrains. The ink-jetting behavior of charged solution under nonuniform electrical field and the nanoscale ablation mechanism of large-area laser lift-off would be devoted. Then the conformal manufacturing principle of flexible curved electronics will be established based on the processing of electrohydrodynamic printing and laser-driven non-contact transfer printing. Several key techniques will be solved including conformal printing plan, parameters match and control for ink-jetting, and dynamic aligning for multi-layer overprinting. A conformal manufacturing platform integrated with software and hardware for flexible curved electronic will be built by combination of the systems of conformal printing, laser lift-off and transfer printing, and the functions of accurate positioning and error compensation. An aircraft smart skin integrated with the flexible curved electronics will be realized and validated, and will be applied as smart skin of one type of unmanned aerial vehicles. The above researches provide the theoretical and technological foundation for conformal manufacturing of flexible curved electronics.

柔性曲面电子具有大面积、可变形、轻质和非平面的特点，在航空航天、信息通讯和健康医疗等领域已显示出巨大的发展空间和应用需求。本项目针对飞行器智能蒙皮为代表的柔性曲面电子的大面积、异质材料、曲面共形制造要求，从器件设计、工艺机理、装备原理等方面围绕“大面积柔性电子曲面共形制造”科学问题开展多学科交叉研究。提出大变形-高稳定性的柔性传感网络设计、几何-物理混合约束下柔性曲面映射方法，揭示非均匀电场作用下带电射流喷射行为和大面积激光剥离纳米碳化机理，建立基于电流体动力喷印-激光剥离转印的曲面共形制造新原理；突破共形喷印轨迹规划与参数匹配、多层套印动态对准等关键技术，建立集共形喷印、激光剥离与曲面转印，以及精密定位、误差补偿等功能的柔性电子曲面共形制造原理样机，实现大面积柔性曲面电子与智能蒙皮的集成及柔性曲面电子功能验证，并应用于某型号无人机的智能蒙皮，为柔性曲面电子制造提供理论基础和技术源泉。

项目针对飞行器智能蒙皮为代表的柔性曲面电子制造要求，围绕“大面积柔性电子曲面共形制造”科学问题，从器件设计、工艺机理、装备原理、蒙皮应用等方面开展多学科交叉研究。1）在器件设计方面，提出了自相似波纹结构设计方法，建立了任意分形结构的递归力学模型；建立柔性智能蒙皮曲面共形模型与判定准则，给出了软体/硬体曲面共形理论模型和设计原则；得到了大面积连续异构型压电传感器网络，比常规传感网络引线数量减少>50%。2）在工艺机理方面，研究光滑曲面激光扫描匹配与机器视觉对准方法，实现了复杂曲面设计坐标与加工坐标的匹配；提出了基于曲面降维与剪纸拼合的智能蒙皮制造方案，实现低维平面工艺制造高维曲面智能蒙皮；提出了螺旋电纺丝直写原理，实现了微米尺度波纹结构制造；提出了超薄（~1µm）柔性电子高可靠激光剥离和主动/被动共形转印工艺，实现柔性电子复杂曲面集成。3）在装备原理方面，研制了柔性电子曲面共形集成制造平台，集成了增减材一体化喷头、主动转印机械手等；提出了“误差转移”的共形喷印规划方法，开发了球形电机运动平台保证喷印速度一致性，并进一步研制机器人化“喷印-转印”共形制造平台。4）在蒙皮应用方面，设计大变形蜂窝蒙皮集成的变形机翼后缘结构，提出一种曲面全覆盖式柔性智能蒙皮技术；提出基于瞬态抑制钳位阵列和FPGA的冲击监测方法，以及多路信号共线的传感网络设计和低功耗信号处理方法；开发了柔性智能蒙皮在飞行器领域的创新应用，实现大规模、低功耗的冲击监测系统，以及某型大飞机尾翼全覆盖测量和6Ma高超音速风洞测量，完成了表面压力/脉动压力/温度/应变/流速等多个参数测量与联合分析。在Science Advances等期刊发表SCI论文57篇、出版英文专著2部；授权/受理发明专利63项，专利成果转化2000余万元；项目团队获6项省部级奖项和高影响力社会奖项，获“国家杰出青年科学基金”1项、“长江学者奖励计划”青年学者2人、国家级青年人才1人、“青年人才托举项目”1人。