Flexible pressure sensors via engineering microstructures for wearable human-machine interaction and health monitoring applications

Highly sensitive and wide-range iontronic pressure sensors with a wheat awn-like hierarchical structure

Flexible pressure sensors with high sensitivity and wide sensing range are highly desired in e-skins and wearable electronics. However, there is always a trade-off between high sensitivity and broad sensing range for most flexible pressure sensors. Herein, an artificial wheat awn-like hierarchical structure is designed onto the dielectric layer of the iontronic pressure sensor, realizing both high sensitivity and broad working range. The sensor is constructed by sandwiching a wheat awn-like polyvinyl alcohol/H3PO4 dielectric layer between two transparent electrodes of silver nanowires/thermoplastic polyurethane/ionic liquid. The obtained sensor exhibits a high precision of 1 Pa, a high sensitivity of 47.65 kPa-1 (1-200 Pa), a wide measurement range from 1 Pa to 238 kPa, short response/recovery time of 13 ms/12 ms, outstanding stability over 6000 cycles, as well as good transparency. Considering these excellent properties, the sensor shows promising potential in health monitoring, human-computer interaction, wearable electronics, etc.

Smart-Adhesive, Breathable and Waterproof Fibrous Electronic Skins

For the need of direct contact with the skin, electronic skins (E-skins) should not only fulfill electric functions, but also ensure comfort during wearing, including permeability, waterproofness, and easy removal. Herein, the study has developed a self-adhesive, detach-on-demand, breathable, and waterproof E-skin (PDSC) for motion sensing and wearable comfort by electrospinning styrene-isoprene block copolymer rubber with carbon black nanosheets as the sensing layer and liner copolymers of N, N-dimethylacrylamide, n-octadecyl acrylate and lauryl methacrylate as the adhesive layer. The high elasticity and microfiber network structure endow the PDSC with good sensitivity and high linearity for strain sensing. The hydrophobic and crystallizable adhesive layer ensures robust, waterproof, and detaching-on-demand skin adhesion. Meanwhile, the fiber structure enables the PDSC good air and water permeability. The integration of electric and wearable functions endows the PDSC with great potential for motion sensing during human activities as both the sensing and wearable performances.

Efficient Fabrication of Bioinspired Flexible Pressure Sensors via Electrohydrodynamic Jet Printing Method

Bioinspired microdevices have made significant strides in various applications including human motion and health detection. However, facile and highly efficient fabrication approach of flexible pressure sensors remains a great challenge. Herein, inspired by the gecko's foot structure, a flexible pressure sensor with microdomes structure is fabricated by tip-assisted on-demand electrohydrodynamic jet (EHD-jet) printing method. Ascribed to the interlocking electrodes with microdome structure, 3D deformation rates are substantially enlarged. When the microdromes structure is under pressure, the resistivity of carbon nanotubes film coated on the surface of microdomes structure will change remarkably. By using the combined effect of assisted tip and ring focusing electrode, the influence and constraints on microstructure fabrication caused by substrate material and morphology are minimized. The desired uniform structures can be adjusted rapidly by changing the printing parameters and liquid properties. High length-height ratio (0.64) of microdomes enhances sensitivity, with minimum detection limit is 2 Pa and response time is 40 ms. Finally, the bionic flexible sensor indicated excellent performance in capable of detecting pressure, sound vibrations and human motion. This work presents a new method for high-efficiency fabrication micro-nano patterns for flexible sensors inspired, which could be used in wearable tech and health monitoring.

Gait Pattern Analysis: Integration of a Highly Sensitive Flexible Pressure Sensor on a Wireless Instrumented Insole

Gait phase monitoring wearable sensors play a crucial role in assessing both health and athletic performance, offering valuable insights into an individual's gait pattern. In this study, we introduced a simple and cost-effective capacitive gait sensor manufacturing approach, utilizing a micropatterned polydimethylsiloxane dielectric layer placed between screen-printed silver electrodes. The sensor demonstrated inherent stretchability and durability, even when the electrode was bent at a 45-degree angle, it maintained an electrode resistance of approximately 3 Ω. This feature is particularly advantageous for gait monitoring applications. Furthermore, the fabricated flexible capacitive pressure sensor exhibited higher sensitivity and linearity at both low and high pressure and displayed very good stability. Notably, the sensors demonstrated rapid response and recovery times for both under low and high pressure. To further explore the capabilities of these new sensors, they were successfully tested as insole-type pressure sensors for real-time gait signal monitoring. The sensors displayed a well-balanced combination of sensitivity and response time, making them well-suited for gait analysis. Beyond gait analysis, the proposed sensor holds the potential for a wide range of applications within biomedical, sports, and commercial systems where soft and conformable sensors are preferred.

Strain Sensors Made of MXene, CNTs, and TPU/PSF Asymmetric Structure Films with Large Tensile Recovery and Applied in Human Health Monitoring

Designing flexible wearable sensors with a wide sensing range, high sensitivity, and high stability is a vulnerable research direction with a futuristic field to study. In this paper, Ti3C2Tx MXene/carbon nanotube (CNT)/thermoplastic polyurethane (TPU)/polysulfone (PSF) composite films with excellent sensor performance were obtained by self-assembly of conductive fillers in TPU/PSF porous films with an asymmetric structure through vacuum filtration, and the porous films were prepared by the phase inversion method. The composite films consist of the upper part with finger-like "cavities" filled by MXene/CNTs, which reduces the microcracks in the conductive network during the tensile process, and the lower part has smaller apertures of a relatively dense resin cortex assisting the recovery process. The exclusive layer structure of the MXene/CNTs/TPU/PSF film sensor, with a thickness of 46.95 μm, contains 0.0339 mg/cm2 single-walled carbon nanotubes (SWNTs) and 0.348 mg/cm2 MXene only, providing functional range (0-80.7%), high sensitivity (up to 1265.18), and excellent stability and durability (stable sensing under 2300 fatigue tests, viable to the initial resistance), endurably cycled under large strains with serious damage to the conductive network. Finally, the MXene/CNTs/TPU/PSF film sensor is usable for monitoring pulse, swallow, tiptoe, and various joint bends in real time and distributing effective electrical signals. This paper implies that the MXene/CNTs/TPU/PSF film sensor has broad prospects in pragmatic applications.

Microstructured Polyelectrolyte Elastomer-Based Ionotronic Sensors with High Sensitivities and Excellent Stability for Artificial Skins

High-performance flexible pressure sensors are highly demanded for artificial tactile sensing. Using ionic conductors as the dielectric layer has enabled ionotronic pressure sensors with high sensitivities owing to giant capacitance of the electric double layer (EDL) formed at the ionic conductor/electronic conductor interface. However, conventional ionotronic sensors suffer from leakage, which greatly hinders long-term stability and practical applications. Herein, a leakage-free polyelectrolyte elastomer as the dielectric layer for ionotronic sensors is synthesized. The mechanical and electrical properties of the polyelectrolyte elastomer are optimized, a micropyramid array is constructed, and it is used as the dielectric layer for an ionotronic pressure sensor with marked performances. The obtained sensor exhibits a sensitivity of 69.6 kPa-1 , a high upper detecting limit on the order of 1 MPa, a fast response/recovery speed of ≈6 ms, and excellent stability under both static and dynamic loads. Notably, the sensor retains a high sensitivity of 4.96 kPa-1 at 500 kPa, and its broad sensing range within high-pressure realm enables a brand-new coding strategy. The applications of the sensor as a wearable keyboard and a quasicontinuous controller for a robotic arm are demonstrated. Durable and highly sensitive ionotronic sensors potentialize high-performance artificial skins for soft robots, human-machine interfaces, and beyond.

Multifunction E-Skin Based on MXene-PA-Hydrogel for Human Behavior Monitoring

Hydrogels have attracted significant attention in various fields, such as smart sensing, human-machine interaction, and biomedicines, due to their excellent flexibility and versatility. However, current hydrogel electronic skins are still limited in stretchability, and their sensing functionality is often single-purpose, making it difficult to meet the requirements of complex environments and multitasking. In this study, we developed an MXene nanoplatelet and phytic acid-coreinforced poly(vinyl alcohol) (PVA) composite, denoted as MXene-PA-PVA. The strong hydrogen bonds formed by the interaction of the different components and the enhancement of chain entanglement result in a significant improvement in the mechanical properties of the PVA/PA/MXene composite hydrogel. This improvement is reflected in an increase of 271.43% in the maximum tensile strain and 35.29% in the maximum fracture stress. Moreover, the composite hydrogel exhibits excellent adhesion, water retention, heat resistance, and conductivity properties. The PVA/PA composite material combined with MXene demonstrates great potential for use as multifunctional sensors for strain and temperature detection with a strain-sensing sensitivity of 3.23 and a resistance temperature coefficient of 8.67. By leveraging the multifunctional characteristics of this composite hydrogel, electronic skin can accurately monitor human behavior and physiological reactions. This advancement opens up new possibilities for flexible electronic devices and human-machine interactions in the future.

Giant flexoelectric response of uniformly dispersed BT-PVDF composite films induced by SDS-assisted treatment

Polymer-ceramic composites are commonly used as flexoelectric films. In existing studies, the flexoelectric effect of composites are generally improved by adjusting the material structures or adding ferroelectric materials. Further improvement of flexoelectric response has encountered a bottleneck. Considering from a new perspective, this study innovatively proposes to prepare the uniformly dispersed BT-PVDF composite films with giant flexoelectric response by surfactant SDS-assisted treatment. According to the engineering applications, tilt sensors have been fabricated with the SDS/BT-PVDF composite films. The prepared tilt sensors can accurately sense the tilt change in a small-angle range (0-10°) between the coaxial connecting parts, the response signal changes significantly (49.25-72.35 mV/°), and the response speed can reach 0.166 s. The research provides a new idea for improving the flexoelectric response and also paves a way for developing tilt sensors through a low-cost, facile, and reliable method, showing potential applications including bending sensing and structural health monitoring.

Perspectives in Wearable Systems in the Human-Robot Interaction (HRI) Field

Due to the advantages of ease of use, less motion disturbance, and low cost, wearable systems have been widely used in the human-machine interaction (HRI) field. However, HRI in complex clinical rehabilitation scenarios has further requirements for wearable sensor systems, which has aroused the interest of many researchers. However, the traditional wearable system has problems such as low integration, limited types of measurement data, and low accuracy, causing a gap with the actual needs of HRI. This paper will introduce the latest progress in the current wearable systems of HRI from four aspects. First of all, it introduces the breakthroughs of current research in system integration, which includes processing chips and flexible sensing modules to reduce the system's volume and increase battery life. After that, this paper reviews the latest progress of wearable systems in electrochemical measurement, which can extract single or multiple biomarkers from biological fluids such as sweat. In addition, the clinical application of non-invasive wearable systems is introduced, which solves the pain and discomfort problems caused by traditional clinical invasive measurement equipment. Finally, progress in the combination of current wearable systems and the latest machine-learning methods is shown, where higher accuracy and indirect acquisition of data that cannot be directly measured is achieved. From the evidence presented, we believe that the development trend of wearable systems in HRI is heading towards high integration, multi-electrochemical measurement data, and clinical and intelligent development.

Monitoring and analysis of cardiovascular pulse waveforms using flexible capacitive and piezoresistive pressure sensors and machine learning perspective

The growing interest in flexible electronics for physiological monitoring, particularly using flexible pressure sensors for cardiovascular pulse waveforms monitoring, has potential applications in cuffless blood pressure measurement and early diagnosis of cardiovascular disease. High sensitivity, fast response time, good pressure resolution and a high signal-to-noise ratio are essential for effective pulse waveform detection. This review focuses on flexible capacitive and piezoresistive pressure sensors, which have seen significant enhancements due to their simple operation, superior performance, wide range of materials, and easy fabrication. The comparison of sensing methods for acquiring pulse waveforms from the wrist artery, device integration configurations, high-quality pulse waveforms collection, and performance analysis of capacitive and piezoresistive sensors are discussed. The review also covers the use of machine learning for analyzing pulse waveforms for cardiovascular disease diagnosis and cuff-less blood pressure monitoring. Lastly, it provides perspectives on current challenges and further advancements in the field.

Reliable and Scalable Piezoresistive Sensors with an MXene/MoS2 Hierarchical Nanostructure for Health Signals Monitoring

The increased popularity of wearable electronic devices has led to a greater need for advanced sensors. However, fabricating pressure sensors that are flexible, highly sensitive, robust, and compatible with large-scale fabrication technology is challenging. This work investigates a piezoresistive sensor constructed from an MXene/MoS2 hierarchical nanostructure, which is obtained through an easy and inexpensive fabrication process. The sensor exhibits a high sensitivity of 0.42 kPa-1 (0-1.5 kPa), rapid response (∼36 ms), and remarkable mechanical durability (∼10,000 cycles at 13 kPa). The sensor has been demonstrated to be successful in detecting human motion, speech recognition, and physiological signals, particularly in analyzing human pulse. These data can be used to alert and identify irregularities in human health. Additionally, the sensing units are able to construct sensor arrays of various sizes and configurations, enabling pressure distribution imaging in a variety of application scenarios. This research proposes a cost-effective and scalable approach to fabricating piezoresistive sensors and sensor arrays, which can be utilized for monitoring human health and for use in human-machine interfaces.

Flexible and Stretchable Pressure Sensors: From Basic Principles to State-of-the-Art Applications

Flexible and stretchable electronics have emerged as highly promising technologies for the next generation of electronic devices. These advancements offer numerous advantages, such as flexibility, biocompatibility, bio-integrated circuits, and light weight, enabling new possibilities in diverse applications, including e-textiles, smart lenses, healthcare technologies, smart manufacturing, consumer electronics, and smart wearable devices. In recent years, significant attention has been devoted to flexible and stretchable pressure sensors due to their potential integration with medical and healthcare devices for monitoring human activity and biological signals, such as heartbeat, respiratory rate, blood pressure, blood oxygen saturation, and muscle activity. This review comprehensively covers all aspects of recent developments in flexible and stretchable pressure sensors. It encompasses fundamental principles, force/pressure-sensitive materials, fabrication techniques for low-cost and high-performance pressure sensors, investigations of sensing mechanisms (piezoresistivity, capacitance, piezoelectricity), and state-of-the-art applications.

A negative-work knee energy harvester based on homo-phase transfer for wearable monitoring devices

Wearable health monitoring devices can effectively capture human body information and are widely used in health monitoring, but battery life is an important bottleneck in its development. A full negative-work energy harvester based on the homo-phase transfer mechanism by analyzing human motion characteristics was proposed in this paper. The system was designed based on the homo-phase transfer mechanism, including a motion input module, gear acceleration module, energy conversion module, and electric energy storage module. The output performance in three human-level, downhill, and running states was tested, respectively. Finally, we have evaluated the feasibility of an energy harvester powering wearable health monitoring devices, and the harvester can generate 17.40 J/day power, which can satisfy the normal operation of a typical health monitoring device. This study has certain promoting significance for the development of a new generation of human health monitoring.

Accurate Nonlinearity and Temperature Compensation Method for Piezoresistive Pressure Sensors Based on Data Generation

Piezoresistive pressure sensors exhibit inherent nonlinearity and sensitivity to ambient temperature, requiring multidimensional compensation to achieve accurate measurements. However, recent studies on software compensation mainly focused on developing advanced and intricate algorithms while neglecting the importance of calibration data and the limitation of computing resources. This paper aims to present a novel compensation method which generates more data by learning the calibration process of pressure sensors and uses a larger dataset instead of more complex models to improve the compensation effect. This method is performed by the proposed aquila optimizer optimized mixed polynomial kernel extreme learning machine (AO-MPKELM) algorithm. We conducted a detailed calibration experiment to assess the quality of the generated data and evaluate the performance of the proposed method through ablation analysis. The results demonstrate a high level of consistency between the generated and real data, with a maximum voltage deviation of only 0.71 millivolts. When using a bilinear interpolation algorithm for compensation, extra generated data can help reduce measurement errors by 78.95%, ultimately achieving 0.03% full-scale (FS) accuracy. These findings prove the proposed method is valid for high-accuracy measurements and has superior engineering applicability.

Recent progress in flexible micro-pressure sensors for wearable health monitoring

In recent years, flexible micro-pressure sensors have been used widely in wearable health monitoring applications due to their excellent flexibility, stretchability, non-invasiveness, comfort wearing and real-time detection. According to the working mechanism of the flexible micro-pressure sensor, it can be classified as piezoresistive, piezoelectric, capacitive and triboelectric types. Herein, an overview of flexible micro-pressure sensors for wearable health monitoring is presented. The physiological signaling and body motions contain a lot of health status information. Thus, this review focuses on the applications of flexible micro-pressure sensors in these fields. Additionally, the contents of sensing mechanism, sensing materials and performance of flexible micro-pressure sensors are introduced in detail. Finally, we predict the future research directions of the flexible micro-pressure sensors, and discuss the challenges in practical applications.

Ultrasensitive Linear Capacitive Pressure Sensor with Wrinkled Microstructures for Tactile Perception

Ultrasensitive flexible pressure sensors with excellent linearity are essential for achieving tactile perception. Although microstructured dielectrics have endowed capacitive sensors with ultrahigh sensitivity, the compromise of sensitivity with increasing pressure is an issue yet to be resolved. Herein, a spontaneously wrinkled MWCNT/PDMS dielectric layer is proposed to realize the excellent sensitivity and linearity of capacitive sensors for tactile perception. The synergistic effect of a high dielectric constant and wrinkled microstructures enables the sensor to exhibit linearity up to 21 kPa with a sensitivity of 1.448 kPa^-1 and a detection limit of 0.2 Pa. Owing to these merits, the sensor monitors subtle physiological signals such as various arterial pulses and respiration. This sensor is further integrated into a fully multimaterial 3D-printed soft pneumatic finger to realize material hardness perception. Eight materials with different hardness values are successfully discriminated, and the capacitance of the sensor varies linearly (R² > 0.975) with increasing hardness. Moreover, the sensitivity to the material hardness can be tuned by controlling the inflation pressure of the soft finger. As a proof of concept, the finger is used to discriminate pork fats with different hardness, paving the way for hardness discrimination in clinical palpation.

Recent progress in flexible pressure sensors based on multiple microstructures: from design to application

Flexible pressure sensors (FPSs) have been widely studied in the fields of wearable medical monitoring and human-machine interaction due to their high flexibility, light weight, sensitivity, and easy integration. To better meet these application requirements, key sensing properties such as sensitivity, linear sensing range, pressure detection limits, response/recovery time, and durability need to be effectively improved. Therefore, researchers have extensively and profoundly researched and innovated on the structure of sensors, and various microstructures have been designed and applied to effectively improve the sensing performance of sensors. Compared with single microstructures, multiple microstructures (MMSs) (including hierarchical, multi-layered and hybrid microstructures) can improve the sensing performance of sensors to a greater extent. This paper reviews the recent research progress in the design and application of FPSs with MMSs and systematically summarizes the types, sensing mechanisms, and preparation methods of MMSs. In addition, we summarize the applications of FPSs with MMSs in the fields of human motion detection, health monitoring, and human-computer interaction. Finally, we provide an outlook on the prospects and challenges for the development of FPSs.

Multifunctional Iontronic Sensor Based on Liquid Metal-Filled Ho llow Ionogel Fibers in Detecting Pressure, Temperature, and Proximity

Fiber-based pressure/temperature sensors are highly desired in wearable electronics because of their natural advantages of good breathability and easy integrability. However, it is still a great challenge to fabricate reliable and highly sensitive fiber-based pressure/temperature sensors via a scalable and facile strategy. Herein, a novel fiber-based iontronic sensor with excellent pressure- and temperature-sensing capabilities is designed by assembling two crossed hollow and porous ionogel fibers filled with liquid metal. Serving as a pressure sensor, a high detection resolution (1.16 Pa), a high sensitivity of 13.30 kPa^-1 (0-2 kPa), and a wide detection range (∼207 kPa) are realized owing to its novel hierarchical structure and the selection of deformable liquid electrodes. As a temperature sensor, it exhibits a high temperature sensitivity of 25.99% °C^-1 (35-40 °C), high resolution of 0.02 °C, and good repeatability and reliability. On the basis of these excellent sensing capabilities, the as-prepared sensor can detect not only pressure signals varied from weak pulse to large joint movements but also the proximity of different objects. Furthermore, a large-area fiber array can be easily woven for acquiring the pressure mapping to intuitively distinguish the location, magnitude, and shape of the loaded object. This work provides a universal strategy to design fiber-shaped iontronic sensors for wearable electronics.

Research Progresses in Microstructure Designs of Flexible Pressure Sensors

Flexible electronic technology is one of the research hotspots, and numerous wearable devices have been widely used in our daily life. As an important part of wearable devices, flexible sensors can effectively detect various stimuli related to specific environments or biological species, having a very bright development prospect. Therefore, there has been lots of studies devoted to developing high-performance flexible pressure sensors. In addition to developing a variety of materials with excellent performances, the microstructure designs of materials can also effectively improve the performances of sensors, which has brought new ideas to scientists and attracted their attention increasingly. This paper will summarize the flexible pressure sensors based on material microstructure designs in recent years. The paper will mainly discuss the processing methods and characteristics of various sensors with different microstructures, and compare the advantages, disadvantages, and application scenarios of them. At the same time, the main application fields of flexible pressure sensors based on microstructure designs will be listed, and their future development and challenges will be discussed.