Highly Sensitive Interlocked Piezoresistive Sensors Based on Ultrathin Ordered Nanocone Array Films and Their Sensitivity Simulation

Research Progress and Application of Multimodal Flexible Sensors for Electronic Skin

In recent years, wearable electronic skin has garnered significant attention due to its broad range of applications in various fields, including personal health monitoring, human motion perception, human-computer interaction, and flexible display. The flexible multimodal sensor, as the core component of electronic skin, can mimic the multistimulus sensing ability of human skin, which is highly significant for the development of the next generation of electronic devices. This paper provides a summary of the latest advancements in multimodal sensors that possess two or more response capabilities (such as force, temperature, humidity, etc.) simultaneously. It explores the relationship between materials and multiple sensing capabilities, focusing on both active materials that are the same and different. The paper also discusses the preparation methods, device structures, and sensing properties of these sensors. Furthermore, it introduces the applications of multimodal sensors in human motion and health monitoring, as well as intelligent robots. Finally, the current limitations and future challenges of multimodal sensors will be presented.

Research on high sensitivity piezoresistive sensor based on structural design

With the popularity of smart terminals, wearable electronic devices have shown great market prospects, especially high-sensitivity pressure sensors, which can monitor micro-stimuli and high-precision dynamic external stimuli, and will have an important impact on future functional development. Compressible flexible sensors have attracted wide attention due to their simple sensing mechanism and the advantages of light weight and convenience. Sensors with high sensitivity are very sensitive to pressure and can detect resistance/current changes under pressure, which has been widely studied. On this basis, this review focuses on analyzing the performance impact of device structure design strategies on high sensitivity pressure sensors. The design of structures can be divided into interface microstructures and three-dimensional framework structures. The preparation methods of various structures are introduced in detail, and the current research status and future development challenges are summarized.

Two-dimensional MXene nanosheets on nano-scale fibrils in hierarchical porous structure to achieve ultra-high sensitivity

The complex hybrid nanostructure combining a two-dimensional (2D) conductive material and a hierarchical nanoscale skeleton plays an important role to enhance its piezoresistive sensitivity. To construct such a novel hybrid nanostructure, a piezoresistive sensor was designed with the following strategy to take the full advantages of 2D MXene and nanoscale fibrils: ethylene oxide propylene oxide random copolymer (EOPO) was grafted to ethylene-vinyl alcohol (EVOH) molecular chains and was foamed by an environmentally-friendly supercritical CO2 (scCO2) foaming technology to fabricate abundant nanoscale EVOH fibrils surrounding micropores; MXene featured as a 2D structure of nanoscale size that strongly interacted with this hierarchical nanoscale skeleton, and MXene not only convolved on nanoscale fibrils to generate bumps but also MXene covered the end of broken fibrils to build spots, and furthermore, MXene adhered on the soft EOPO embedded EVOH fibrils to form wrinkles, in which these bumps, spots and wrinkles assembled by highly conductive 2D MXene offered sufficient contacts when the hierarchical nanoscale skeleton was compressed (these contacts would then destruct when the skeleton recovered). Such an elaborated hybrid nanostructural design exploits the full potential of 2D MXene and hence achieves an ultra-high sensitivity of 6895.0 kPa-1 for this fabricated MXene piezoresistive sensor.

Heterogeneous Multi-Material Flexible Piezoresistive Sensor with High Sensitivity and Wide Measurement Range

Flexible piezoresistive sensors (FPSs) have the advantages of compact structure, convenient signal acquisition and fast dynamic response; they are widely used in motion detection, wearable electronic devices and electronic skins. FPSs accomplish the measurement of stresses through piezoresistive material (PM). However, FPSs based on a single PM cannot achieve high sensitivity and wide measurement range simultaneously. To solve this problem, a heterogeneous multi-material flexible piezoresistive sensor (HMFPS) with high sensitivity and a wide measurement range is proposed. The HMFPS consists of a graphene foam (GF), a PDMS layer and an interdigital electrode. Among them, the GF serves as a sensing layer, providing high sensitivity, and the PDMS serves as a supporting layer, providing a large measurement range. The influence and principle of the heterogeneous multi-material (HM) on the piezoresistivity were investigated by comparing the three HMFPS with different sizes. The HM proved to be an effective way to produce flexible sensors with high sensitivity and a wide measurement range. The HMFPS-10 has a sensitivity of 0.695 kPa^-1, a measurement range of 0-14,122 kPa, fast response/recovery (83 ms and 166 ms) and excellent stability (2000 cycles). In addition, the potential application of the HMFPS-10 in human motion monitoring was demonstrated.

Magnetically assisted drop-on-demand 3D printing of microstructured multimaterial composites

Microstructured composites with hierarchically arranged fillers fabricated by three-dimensional (3D) printing show enhanced properties along the fillers’ alignment direction. However, it is still challenging to achieve good control of the filler arrangement and high filler concentration simultaneously, which limits the printed material’s properties. In this study, we develop a magnetically assisted drop-on-demand 3D printing technique (MDOD) to print aligned microplatelet reinforced composites. By performing drop-on-demand printing using aqueous slurry inks while applying an external magnetic field, MDOD can print composites with microplatelet fillers aligned at set angles with high filler concentrations up to 50 vol%. Moreover, MDOD allows multimaterial printing with voxelated control. We showcase the capabilities of MDOD by printing multimaterial piezoresistive sensors with tunable performances based on the local microstructure and composition. MDOD thus creates a large design space to enhance the mechanical and functional properties of 3D printed electronic or sensing devices using a wide range of materials.

3D printed composites with hierarchically arranged fillers have been challenging to fabricate. Here, the authors make use of magnetically assisted droplet-based printing to 3D print voxelated structures with high filler content, localized control of filler material, and orientation.

Ordered Nanopillar Arrays of Low Dynamic Noise Dry Bioelectrodes for Electrocardiogram Surface Monitoring

Flexible bioelectric dry electrodes are an important part of long-term medical healthcare monitoring systems. In this study, a new method is proposed for the preparation of dry electrodes with micronanopillar arrays structured by designing dimensionally tunable anodized aluminum oxide (AAO) templates, by which polyaniline/thermoplastic polyurethane single-layer micronanopillar array structured dry electrodes (PANI/TPU-SE) and polyaniline/thermoplastic polyurethane double-layer micronanopillar array structured dry electrodes (PANI/TPU-DE) are prepared. Compared with the planar structure, the micronanopillar array structure can reduce the contact gap between the electrode and skin and increase the contact area, thus exhibiting lower contact impedance and higher signal quality. At 0.1 Hz, the impedances of the wet electrode, PANI/TPU-DE300, PANI/TPU-SE10, and planar structure electrodes are 269.5 kΩ, 375.5 kΩ, 398.1 kΩ, and 2.257 MΩ, respectively, and the impedance value for PANI/TPU-DE300 is smaller than that for PANI/TPU-SE10 and closer to that for the wet electrode. In addition, because the surface of the micronanostructure can conform to the human skin, about 210.7% increase in the peel strength of double-layer structure electrodes compared to flat structure electrodes, it shows a low baseline drift in the dynamic ECG measurement, and the signal-to-noise ratio in the walking state can reach 21.33 ± 5.4775 dB. Therefore, the prepared bioelectric dry electrode has a wide application prospect in the fields of wearable medical monitoring.

Interlinked Microcone Resistive Sensors Based on Self-Assembly Carbon Nanotubes Film for Monitoring of Signals

Flexible pressure sensors still face difficulties achieving a constantly adaptable micronanostructure of substrate materials. Interlinked microcone resistive sensors were fabricated by polydimethylsiloxane (PDMS) nanocone array. PDMS nanocone array was achieved by the second transferring tapered polymethyl methacrylate (PMMA) structure. In addition, self-assembly 2D carbon nanotubes (CNTs) networks as a conducting layer were prepared by a low-cost, dependable, and ultrafast Langmuir−Blodgett (LB) process. In addition, the self-assembled two-dimensional carbon nanotubes (CNTs) network as a conductive layer can change the internal resistance due to pressure. The results showed that the interlinked sensor with a nanocone structure can detect the external pressure by the change of resistivity and had a sensitive resistance change in the low pressure (<200 Pa), good stability through 2800 cycles, and a detection limit of 10 kPa. Based on these properties, the electric signals were tested, including swallowing throat, finger bending, finger pressing, and paper folding. The simulation model of the sensors with different structural parameters under external pressure was established. With the advantages of high sensitivity, stability, and wide detection range, this sensor shows great potential for monitoring human motion and can be used in wearable devices.

Biomimetic Microstructured Antifatigue Fracture Hydrogel Sensor for Human Motion Detection with Enhanced Sensing Sensitivity

Antifatigue fracture performance and high sensing sensitivity are key characteristics for hydrogel sensors used in flexible electronic applications. Herein, inspired by human muscle tissues and epidermal skin tissues, an effective and straightforward strategy is proposed to fabricate hydrogel sensors for detecting human motion with antifatigue fracture performance and high sensing sensitivity. The crystalline regions and orientation along the stretching direction of cellulose nanofiber@carbon nanotube nanohybrids in the hydrogels provide antifatigue fracture performance (the crack does not expand after 2000 stretching cycles, and the fatigue threshold was calculated to be 187 J/m2), which protects hydrogels from severe damage during long-term use. In addition, the microstructured surfaces of the hydrogels with a random height distribution increase the contact area and improve the response to weak stimuli, resulting in a sensing sensitivity of 1.11 kPa-1, 18 times higher than that of a flat hydrogel. This sensing sensitivity is higher than those of most of the hydrogel-based pressure sensors that have been reported earlier. By integrating antifatigue fracture performance and enhanced sensing sensitivity, biomimetic microstructured hydrogel sensors show great potential for use in future flexible electronic applications.

Flexible and high-performance piezoresistive strain sensors based on multi-walled carbon nanotubes@polyurethane foam

Flexible wearable pressure sensors have attracted special attention in the last 10 years due to their great potential in health monitoring, activity detection and as electronic skin. However, it is still a great challenge to develop high sensitivity, fast response, and good reliable stability through a simple and reproducible large-scale fabrication process. Here, we develop a simple and efficient method to fabricate three-dimensional (3D) light-weight piezoresistive sensing materials by coating multi-walled carbon nanotubes (MWCNTs) on the surface of polyurethane (PU) foam using a dip-spin coating process. The PU foam prepared with SEBS-g-MAH and polyether polyols has high elasticity and good stability in MWCNTs/DMF solution. Subsequently, a piezoresistive sensor was assembled with the prepared MWCNTs/PU composite foam and copper foil electrodes. The assembled pressure sensor has high sensitivity (62.37 kPa-1), a wide working range (0-172.6 kPa, 80% strain), a fast response time (less than 0.6 s), and reliable repeatability (≥2000 cycles). It has shown potential application in real-time human motion detection (e.g., arm bending, knee bending), and monitoring the brightness of LED lights.

Washable Patches with Gold Nanowires/Textiles in Wearable Sensors for Health Monitoring

Textile-based flexible electronic devices have attracted tremendous attention in wearable sensors due to their excellent skin affinity and conformability. However, the washing process of such devices may damage the electronic components. Here, a textile-based piezoresistive sensor with ultrahigh sensitivity was fabricated through the layered integration of gold nanowire (AuNW)-impregnated cotton fabric and silver ink screen-printed nylon fabric electrodes, sealing with Parafilm. The prepared piezoresistive sensing patch exhibits outstanding performance, including high sensitivity (914.970 kPa^-1, <100 Pa), a fast response time (load: 38 ms, recovery: 34 ms), and a low detection limit (0.49 Pa). More importantly, it can maintain a stable signal output even after 30 000 s of loading-unloading cycles. Furthermore, this sensing patch can efficiently detect breathing, pulse, heart rate, and joint movements during the activities. After five cycles of mechanical washing, the piezoresistive performance keeps 90.3%, demonstrating the high feasibility of this sensor in practical applications. This sensor has a simple fabrication, with good fatigue resistance and durability due to its all-fabric core element. It provides a strategy to address the machine-washing issues in textile electronics. This washable textile sensor is expected to show significant potential in future applications of health monitoring, human-machine interfaces, and artificial skin.

Force-Sensitive Interface Engineering in Flexible Pressure Sensors: A Review

Flexible pressure sensors have received extensive attention in recent years due to their great importance in intelligent electronic devices. In order to improve the sensing performance of flexible pressure sensors, researchers are committed to making improvements in device materials, force-sensitive interfaces, and device structures. This paper focuses on the force-sensitive interface engineering of the device, which listing the main preparation methods of various force-sensitive interface microstructures and describing their respective advantages and disadvantages from the working mechanisms and practical applications of the flexible pressure sensor. What is more, the device structures of the flexible pressure sensor are investigated with the regular and irregular force-sensitive interface and accordingly the influences of different device structures on the performance are discussed. Finally, we not only summarize diverse practical applications of the existing flexible pressure sensors controlled by the force-sensitive interface but also briefly discuss some existing problems and future prospects of how to improve the device performance through the adjustment of the force-sensitive interface.

Development of High-Sensitivity Piezoresistive Sensors Based on Highly Breathable Spacer Fabric with TPU/PPy/PDA Coating

In recent years, the research of flexible sensors has become a hot topic in the field of wearable technology, attracting the attention of many researchers. However, it is still a difficult challenge to prepare low-cost and high-performance flexible sensors by a simple process. Three-dimensional spacer fabric (SF) are the ideal substrate for flexible pressure sensors due to its good compression resilience and high permeability (5747.7 mm/s, approximately 10 times that of cotton). In this paper, Thermoplastic polyurethane/Polypyrrole/Polydopamine/Space Fabric (TPU/PPy/PDA/SF) composite fabrics were prepared in a simple in-situ polymerization method by sequentially coating polydopamine (PDA) and Polypyrrole (PPy) on the surface of SF, followed by spin-coating of different polymers (thermoplastic polyurethane (TPU), polydimethylsiloxane (PDMS) and Ecoflex) on the PPy/PDA/SF surface. The results showed that the TPU/PPy/PDA/SF pressure sensors prepared by spin-coating TPU at 900 rpm at a concentration of 0.3 mol of pyrrole monomer (py) and a polymerization time of 60 min have optimum sensing performance, a wide working range (0−10 kPa), high sensitivity (97.28 kPa−1), fast response (60 ms), good cycling stability (>500 cycles), and real-time motion monitoring of different parts of the body (e.g., arms and knees). The TPU/PPy/PDA/SF piezoresistive sensor with high sensitivity on a highly permeable spacer fabric base developed in this paper has promising applications in the field of health monitoring.

Fingerprint-Inspired Strain Sensor with Balanced Sensitivity and Strain Range Using Laser-Induced Graphene

Sensitivity and strain range are two mutually exclusive features of strain sensors, where a significant improvement in flexibility is usually accompanied by a reduction in sensitivity. The skin of a human fingertip, due to its undulating fingerprint pattern, can easily detect environmental signals and enhances sensitivity without losing elasticity. Inspired by this characteristic, laser-induced graphene (LIG) with a fingerprint structure is prepared in one step on a polyimide (PI) film and transferred into an Ecoflex substrate to assemble resistive strain sensors. Experimentally, the fingerprint-inspired strain sensor exhibits a superfast response time (∼70 ms), balanced sensitivity and strain range (a gauge factor of 191.55 in the 42-50% strain range), and good reliability (>1500 cycles). Self-organized microcracks, initiated in weak mechanical areas, cause prominent resistance changes during reconnection/disconnection but irreversibly fail after excessive stretching. The robust function of fingerprint-inspired sensors is further demonstrated by real-time monitoring of tiny pulses, large body movements, gestures, and voice recognition.

Skin-friendly corrugated multilayer microspherical sensor fabricated with silk fibroin, poly (lactic-co-glycolic acid), polyaniline, and kappa-carrageenan for wide range pressure detection

To enlarge the linear detection range without sacrificing the sensitivity is one of the urgent problems in the development of high-performance piezoresistive flexible sensors. Inspired by a multilayer corrugated board, this study develops a new multilayer microspherical sensor in which conductive core-shell SiO₂/Polyaniline (PANI) (PS) microspheres serve as active particles, while insulated silk fibroin (SF)/poly lactic-co-glycolic acid (PLGA) (SP) fibers are used as the support. The size of conductive microspheres attached to the insulated layer is controllable. The multiple layers of assembly endow the flexible sensor with a high sensitivity (0.071 kPa^-1) and a wide linear detection (from 10 Pa to 380 kPa) simultaneously. This corrugated sensor also have a fast response time (145 ms) and an excellent durability (over 2000 cycles), and it can be used to detect human joint pressure signals and transmit encrypted information. Moreover, flexible keyboard, safety protection of machinery, as well as object position tracking can be achieved based on this sensor. Most importantly, the sensor encapsulated by biological polysaccharide kappa-carrageenan (KC) is skin-friendly and breathable, and it can be decomposed in 90 °C hot water. In conclusion, this multilayer microspherical sensor presents great potential for flexible wearable devices.