ZTACH ® ACE: Robust Interconnections for Military Wearable Sensors

Wearable sensors provide an enhanced degree of warfighter protection by enabling real-time and continuous monitoring of health metrics, biological/chemical threats, location, and biofeedback of troops. It is critical for the warfighter that wearable sensing solutions be stretchable, lightweight and reliable to provide the benefits of the sensing technology without physical hindrance. To advance the full integration of sensors into garments and sensor suites and eliminate the need for rigid substrates that limit the utility of these garments, SunRay Scientific has developed a full solution to include the interconnect and encapsulation of electrical components onto flexible substrates, without the need for a rigid circuit board and plastic case. The solution includes stretchable inks, a flexible anisotropic conductive epoxy to connect circuit elements, and a stretchable encapsulant. Furthermore, this manufacturing solution allows for a no pressure, low-temperature cure, robust adhesion to various substrates, and ease of high-volume production using industry-standard processes and equipment. This project aims to demonstrate the applicability of SunRay Scientific’s anisotropic conductive epoxies, inks and encapsulants for flexible hybrid electronics integration on fabric through a variety of interconnect test structures that can be used to attach silicon devices, electronic modules, passive components and other flex boards to functionalized textiles.