Stretchable Anisotropic Conductive Film with Position‐Registered Conductive Microparticles Used for Strain‐Insensitive Ionic Interfacing in Stretchable Ionic Sensors

Abstract Numerous approaches are explored to achieve precise position registry of microparticles (MPs) with minimal defects; however, MP assembly in a periodic pattern or an arbitrary manner has been a challenging issue over the past several decades. Utilizing the position‐registered conductive MPs, polymer composites of the MPs are used as anisotropic conductive film (ACF) and soft interfacing. One of the remaining challenges is maintaining the MP positions while producing or utilizing the ACF. This study proposes a simple strategy to produce a stretchable ACF (S‐ACF) by mechanical rubbing, without disturbing the MP positions during the production and use. A practical means of precise MP positioning on a ultraviolet (UV)‐patternable soft template is investigated first. This study investigates, through both experiment and finite element method calculation, the relationship between local adhesion of the template and mechanical rubbing variables (pressure, rubbing velocity, and MP size). Based on this exploration, a fast and simple method to fabricate large‐area S‐ACF is presented. This study demonstrates that the S‐ACF can be used for electronic interfacing in stretchable devices and for ionic interfacing to remove the effect of external mechanical force in ionic sensors.