Tuning Strain Sensor Performance via Programmed Thin-Film Crack Evolution

Quasi-1D Conductive Network Composites for Ultra-Sensitive Strain Sensing

Highly performance flexible strain sensor is a crucial component for wearable devices, human-machine interfaces, and e-skins. However, the sensitivity of the strain sensor is highly limited by the strain range for large destruction of the conductive network. Here the quasi-1D conductive network (QCN) is proposed for the design of an ultra-sensitive strain sensor. The orientation of the conductive particles can effectively reduce the number of redundant percolative pathways in the conductive composites. The maximum sensitivity will reach the upper limit when the whole composite remains only "one" percolation pathway. Besides, the QCN structure can also confine the tunnel electron spread through the rigid inclusions which significantly enlarges the strain-resistance effect along the tensile direction. The strain sensor exhibits state-of-art performance including large gauge factor (862227), fast response time (24 ms), good durability (cycled 1000 times), and multi-mechanical sensing ability (compression, bending, shearing, air flow vibration, etc.). Finally, the QCN sensor can be exploited to realize the human-machine interface (HMI) application of acoustic signal recognition (instrument calibration) and spectrum restoration (voice parsing).

Achieving a Wide-Range Linear Piezoresistive Response in Electrowritten Soft-Hard Polymer Blends via Salami-Inspired Heterostructure Design

Flexible electronics capable of acquiring high-precision signals are in great demand for the development of the internet of things and intelligent artificial. However, it is currently a challenge to simultaneously achieve high signal linearity and sensitivity for stretchable resistive sensors over a wide strain range toward advanced application scenarios requiring high signal accuracy, e.g., sophisticated physiological signal discrimination and displacement measurement. Herein, a film strain sensor, which has an electrical and mechanical dual heterostructure, was fabricated via a direct near-field electrowriting and molecule-guided in situ growth of silver nanoparticles with different concentrations on high-modulus polystyrene domains and low-modulus styrene-butadiene copolymers with a salami-like morphology. Mechanism analyses from both theoretical and experimental investigations reveal that the salami-like heteromodulus microstructure regulates microcrack propagation routes, while the heteroconductivity changes the electron transport paths and amplifies the resistance increase during crack propagation. Therefore, the as-designed strain sensor shows a linear resistive response within ca. 70% strain with a gauge factor of 25, unveiling a simple and scalable strategy for trading off signal linearity and sensitivity over a wide strain range for the fabrication of high-performance linear strain sensors.

Highly Stretchable and Fluorescent Visualizable Thermoplastic Polyurethane/Tetraphenylethylene Plied Yarn Strain Sensor with Heterogeneous and Cracked Structure for Human Health Monitoring

Smart wearable technology has been more and more widely used in monitoring and prewarning of human health and safety, while flexible yarn-based strain sensors have attracted extensive research interest due to their ability to withstand greater external strain and their significant application potential in real-time monitoring of human motion and health signals. Although several strain sensors based on yarn structures have been reported, it remains challenging to strike a balance between high sensitivity and wide strain ranges. At the same time, visual signal sensing is expected to be used in strain sensors thanks to its intuitiveness. In this work, thermoplastic polyurethane (TPU) and tetraphenylethylene (TPE) were wet-spun to fabricate flexible fluorescent fibers used as the substrate of the sensor, followed by the drop addition of polydimethylsiloxane (PDMS) beads and curing to produce a heterogeneous structure, which were further twisted into a plied yarn. Finally, a visualizable flexible yarn strain sensor based on solidified liquid beads and crack structure was obtained by loading polydopamine (PDA) and polypyrrole (PPy) in situ. The sensor exhibited high sensitivity (the GF value was 58.9 at the strain range of 143-184%), a wide working strain range (0-184%), a low monitoring limit (<0.1%), a fast response (58.82 ms), reliable responses at different frequencies, and excellent cycle durability (over 2000 cycles). At the same time, the yarn strain sensor also had excellent photothermal characteristics and a fluorescence crack visualization effect. These attractive advantages enabled yarn strain sensors to accurately monitor various human activities, showing great application potential in health monitoring, personalized medical diagnosis, and other aspects.

Highly stable and strain-insensitive metal film conductors via manipulating strain distribution

Metal film-based stretchable conductors are essential elements of flexible electronics for wearable, biomedical, and robotic applications, which require strain-insensitive high conductivity over a wide strain range and excellent cyclic stability. However, they suffer from serious electrical failure under monotonic and cyclic tensile loading at a small strain due to the uncontrolled film cracking behavior. Here, we propose a novel in-plane crack control strategy of engineering hierarchical microstructures to achieve outstanding electromechanical performance via harnessing the strain distribution in metal films. The wrinkles delay the crack initiation at undercuts which should be the most vulnerable sites during the stretching process. The surface protrusions/grooves/undercuts inhibit the crack propagation because of the effective strain redistribution. In addition, hierarchical microstructures significantly improve cyclic stability due to the strong interfacial adhesion and stable crack patterns. The metal film-based conductors exhibit ultrahigh strain-insensitive conductivity (1.7 × 107 S m-1), negligible resistance change (ΔR/R0 = 0.007) over an ultra-wide strain range (>200%), and excellent cyclic strain durability (>15 000 cycles at 100% strain). A range of metal films was explored to establish the universality of this strategy, including ductile copper and silver, as well as brittle molybdenum and high entropy alloy. We demonstrate the strain-insensitive electrical functionality of a metal film-based conductor in a flexible light-emitting diode circuit.

High Sensitivity, Wide Linear-Range Strain Sensor Based on MXene/AgNW Composite Film with Hierarchical Microcrack

Stretchable strain sensors suffer the trade-off between sensitivity and linear sensing range. Developing sensors with both high sensitivity and wide linear range remains a formidable challenge. Different from conventional methods that rely on the structure design of sensing nanomaterial or substrate, here a heterogeneous-surface strategy for silver nanowires (AgNWs) and MXene is proposed to construct a hierarchical microcrack (HMC) strain sensor. The heterogeneous surface with distinct differences in cracks and adhesion strengths divides the sensor into two regions. One region contributes to high sensitivity through penetrating microcracks of the AgNW/MXene composite film during stretching. The other region maintains conductive percolation pathways to provide a wide linear sensing range through network microcracks. As a result, the HMC sensor exhibits ultrahigh sensitivity (gauge factor ≈ 244), broad linear range (ɛ = 60%, R2 ≈ 99.25%), and fast response time (<30 ms). These merits are confirmed in the detection of large and subtle human motions and digital joint movement for Morse coding. The manipulation of cracks on the heterogeneous surface provides a new paradigm for designing high-performance stretchable strain sensors.

Switching ultra-stretchability and sensitivity in metal films for electronic skins: a pufferfish-inspired, interlayer regulation strategy

The booming development of electronic skins necessitates stretchable electrodes and flexible sensors that exhibit distinctly opposite requirements of electromechanical properties, both of which are difficult to be fulfilled on a single material. Here, a pufferfish-inspired, interlayer regulation strategy is proposed that realizes the above opposite properties in simple metal films, exhibiting either ultra-stretchability (295% strain) or sensitivity (maximum GF: ∼5500) on demand. It is revealed that the stretchability of the intrinsically strain-sensitive metal films can be improved by ∼20-fold via regulating the surface morphology of the inserted interlayer, accompanied by an intriguing transition in film cracking behavior from cut-through cracks to network patterns. By featuring these two antithetical but valuable properties, common metal films can be applied as diverse sensors and stretchable electrodes in electronic skins, showing application prospects in healthcare monitoring, human-machine interaction, and engineering services. Our proposed strategy substantially advances the application of metal film conductors in flexible electronics and broadens the horizons for developing more sophisticated electronic skins by interlayer engineering.

Revealing the improved sensitivity of PEDOT:PSS/PVA thin films through secondary doping and their strain sensors application

The field of strain sensing involves the ability to measure an electrical response that corresponds to a strain. The integration of synthetic and conducting polymers can create a flexible strain sensor with a wide range of applications, including soft robotics, sport performance monitoring, gaming and virtual reality, and healthcare and biomedical engineering. However, the use of insulating synthetic polymers can impede the semiconducting properties of sensors, which may reduce sensor sensitivity. Previous research has shown that the doping process can significantly enhance the electrical performance and ionic conduction of conducting polymers, thereby strengthening their potential for use in electronic devices. However the full effects of secondary doping on the crystallinity, stretchability, conductivity, and sensitivity of conducting polymer blends have not been studied. In this study, we investigated the effects of secondary doping on the properties of poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate)/poly(vinyl alcohol) (PEDOT:PSS/PVA) polymer blend thin films and their potential use as strain sensors. The thin films were prepared using a facile drop-casting method. Morphology analysis using profilometry and atomic force microscopy confirmed the occurrence of phase segregation and revealed surface roughness values. This evidence provided a comprehensive understanding of the chemical interactions and physical properties of the thin films, and the effects of doping on these properties. The best films were selected and applied as sensitive strain sensors. EG-PEDOT:PSS/PVA thin films showing a significant increase of conductivity values from the addition of 1 vol% to 12 vol% addition, with conductivity values of 8.51 × 10^-5 to 9.42 × 10^-3 S cm^-1. Our 12% EG-PEDOT:PSS/PVA sensors had the highest GF value of 2000 too. We compared our results with previous studies on polymeric sensors, and it was found that our sensors quantitatively had better GF values. Illustration that demonstrates the DMSO and EG dopant effects on PEDOT:PSS structure through bonding interaction, crystallinity, thermal stability, surface roughness, conductivity and stretchability was also provided. This study suggests a new aspect of doping interaction that can enhance the conductivity and sensitivity of PEDOT:PSS for device applications.

Venation-Mimicking, Ultrastretchable, Room-Temperature-Attachable Metal Tapes for Integrated Electronic Skins

Future electronic skin systems require stretchable conductors and low-temperature integration of external components, which remains challenging for traditional metal films. Herein, a bioinspired design concept is reported to endow metal films with 200% stretchability as well as room-temperature integration capability with diverse components. It is revealed that by controllable implantation of defects, distinctive venation-mimicking cracking modes can be induced in strained metal films, leading to profound stretchability regulation. An intriguing exponential-to-linear transition of the film electromechanical performance is observed, which is elucidated by a unified model covering the essence of all modes. Combined with room-temperature integration capability, an integrated electronic skin is constructed with metal films serving as stretchable electrodes, diverse sensors, and "tapes" to attach subcomponents, showing prospects in helping disabled people. This one-step, defect implantation strategy is applicable to common metals without special substrate treatments, which enables fascinating ultrastretchable metal film conductors with low-temperature integration capability to spark more sophisticated flexible electronic systems.