Sponge-Hosting Polyaniline Array Microstructures for Piezoresistive Sensors with a Wide Detection Range and High Sensitivity

Recent progress in surface engineering methods and advanced applications of flexible polymeric foams

Polymeric foams, also known as three-dimensional (3D) polymeric sponges, are lightweight, flexible, compressible, and possess a high surface area compared with other bulk polymers. These sponges have traditionally been used for mattresses or seat cushions in homes, offices, aircraft, automobiles, and trains, and to insulate against heat, electricity, and noise. Recently, the demand for modern materials has expanded the application of polymeric foams to various high-value technologies, including in areas that need high flame retardancy, flame sensors, oil/water separation, metal adsorption, solar steam generation, piezoresistivity, electromagnetic interference shielding, thermal energy storage, catalysis, supercapacitors, batteries, and triboelectric energy harvesting. Proper modification of foams is a prerequisite for their use in high-value applications. Several new strategies for the surface coating of 3D porous foams and novel emerging applications have been recently developed. Therefore, in this review, current advances in the field of surface coating and the application of 3D polymeric foams are discussed. A brief background on 3D polymeric foams, including the unique properties and benefits of polymeric sponges and their routes of synthesis, is presented. Different coating strategies for polymeric sponges are discussed, and their advantages and drawbacks are highlighted. Different advanced applications of polymeric sponges, in conjunction with specific and detailed examples of the above-mentioned applications, are also described. Finally, challenges and potential applications related to the coating of polymeric foams are discussed. We envisage that this review will be useful to facilitate further research, promote continued efforts on the advanced applications mentioned above, and provide new stimuli for the design of novel polymeric sponges for future modern applications.

A Novel Resistive Sensor Network Utilizing an SAP-Enhanced Ionic Layer and CNT Doping for Multipoint Pressure Measurement

Amidst the rapid advancements in flexible electronics, flexible pressure sensors have achieved widespread applications in fields such as wearable devices and motion monitoring. Nevertheless, it is still a challenge to design a sensor with high sensitivity, cost-effectiveness, and a simplified manufacturing process. This paper introduces a piezoresistive sensor built upon a composite conductive filler. The sensor incorporates a super absorbent polymer (SAP) to absorb a phosphoric acid solution and doped carbon nanotubes as the composite conductive filler. In contrast to conventional rigid conductive fillers, the elastic polymer SAP enhances the sensor's stability significantly by exhibiting superior compatibility with the polydimethylsiloxane matrix, all the while reducing its Young's modulus. This work aims to theoretically elucidate the underlying principles that enable the sensor to achieve high sensitivity. It focuses on the induction of charge carriers due to pressure, which leads to the formation of a conductive pathway and subsequent changes in resistance, thus facilitating precise pressure detection. The paper also discusses the effects of piezoresistive layers with varying thicknesses and conductive fillers on the sensor's output performance. The results highlight the sensor's high sensitivity (0.094 kPa-1), rapid response time (105 ms), and exceptional cyclic load/unload stability (>5000 cycles). Furthermore, this paper establishes a versatile sensing network by integrating a portable inductance, capacitance, and resistance instrument with a programmable logic controller module. Compared to individual sensors, this system enables multipoint measurements, offering high spatial resolution and real-time monitoring capabilities, significantly expanding its overall practicality.

MXene/PPy@PDMS sponge-based flexible pressure sensor for human posture recognition with the assistance of a convolutional neural network in deep learning

The combination of flexible sensors and deep learning has attracted much attention as an efficient method for the recognition of human postures. In this paper, an in situ polymerized MXene/polypyrrole (PPy) composite is dip-coated on a polydimethylsiloxane (PDMS) sponge to fabricate an MXene/PPy@PDMS (MPP) piezoresistive sensor. The sponge sensor achieves ultrahigh sensitivity (6.8925 kPa-1) at 0-15 kPa, a short response/recovery time (100/110 ms), excellent stability (5000 cycles) and wash resistance. The synergistic effect of PPy and MXene improves the performance of the composite materials and facilitates the transfer of electrons, making the MPP sponge at least five times more sensitive than sponges based on each of the individual single materials. The large-area conductive network allows the MPP sensor to maintain excellent electrical performance over a large-scale pressure range. The MPP sensor can detect a variety of human body activity signals, such as radial artery pulse and different joint movements. The detection and analysis of human motion data, which is assisted by convolutional neural network (CNN) deep learning algorithms, enable the recognition and judgment of 16 types of human postures. The MXene/PPy flexible pressure sensor based on a PDMS sponge has broad application prospects in human motion detection, intelligent sensing and wearable devices.

Temperature-Immune, Wide-Range Flexible Robust Pressure Sensors for Harsh Environments

Flexible pressure sensors possess vast potential for various applications such as new energy batteries, aerospace engines, and rescue robots owing to their exceptional flexibility and adaptability. However, the existing sensors face significant challenges in maintaining long-term reliability and environmental resilience when operating in harsh environments with variable temperatures and high pressures (∼MPa), mainly due to possible mechanical mismatch and structural instability. Here, we propose a composite scheme for a flexible piezoresistive pressure sensor to improve its robustness by utilizing material design of near-zero temperature coefficient of resistance (TCR), radial gradient pressure-dividing microstructure, and flexible interface bonding process. The sensing layer comprising multiwalled carbon nanotubes (MWCNTs), graphite (GP), and thermoplastic polyurethane (TPU) was optimized to achieve a near-zero temperature coefficient of resistance over a temperature range of 25-70 °C, while the radial gradient microstructure layout based on pressure division increases the range of pressure up to 2 MPa. Furthermore, a flexible interface bonding process introduces a self-soluble transition layer by direct-writing TPU bonding solution at the bonding interface, which enables the sensor to achieve signal fluctuations as low as 0.6% and a high interface strength of up to 1200 kPa. Moreover, it has been further validated for its capability of monitoring the physiological signals of athletes as well as the long-term reliable environmental resilience of the expansion pressure of the power cell. This work demonstrates that the proposed scheme sheds new light on the design of robust pressure sensors for harsh environments.

Ultra-Tough Waterborne Polyurethane-Based Graft-Copolymerized Piezoresistive Composite Designed for Rehabilitation Training Monitoring Pressure Sensors

Effective training is crucial for patients who need rehabilitation for achieving optimal recovery and reducing complications. Herein, a wireless rehabilitation training monitoring band with a highly sensitive pressure sensor is proposed and designed. It utilizes polyaniline@waterborne polyurethane (PANI@WPU) as a piezoresistive composite material, which is prepared via the in situ grafting polymerization of PANI on the WPU surface. WPU is designed and synthesized with tunable glass transition temperatures ranging from -60 to 0 °C. Dipentaerythritol (Di-PE) and ureidopyrimidinone (UPy) groups are introduced, endowing the material with good tensile strength (14.2 MPa), toughness (62 MJ-1 m-3 ), and great elasticity (low permanent deformation: 2%). Di-PE and UPy enhance the mechanical properties of WPU by increasing the cross-linking density and crystallinity. Combining the toughness of WPU and the high-density microstructure derived by hot embossing technology, the pressure sensor exhibits high sensitivity (168.1 kPa-1 ), fast response time (32 ms), and excellent stability (10 000 cycles with 3.5% decay). In addition, the rehabilitation training monitoring band is equipped with a wireless Bluetooth module, which can be easily applied to monitor the rehabilitation training effect of patients using an applet. Therefore, this work has the potential to significantly broaden the application of WPU-based pressure sensors for rehabilitation monitoring.

Highly sensitive, wide-pressure and low-frequency characterized pressure sensor based on piezoresistive-piezoelectric coupling effects in porous wood

Lightweight and highly compressible materials have received considerable attention in flexible pressure sensing devices. In this study, a series of porous woods (PWs) are produced by chemical removal of lignin and hemicellulose from natural wood by tuning treatment time from 0 to 15 h and extra oxidation through H₂O₂. The prepared PWs with apparent densities varying from 95.9 to 46.16 mg/cm³ tend to form a wave-shaped interwoven structure with improved compressibility (up to 91.89 % strain under 100 kPa). The sensor assembled from PW with treatment time of 12 h (PW-12) exhibits the optimal piezoresistive-piezoelectric coupling sensing properties. For the piezoresistive properties, it has high stress sensitivity of 15.14 kPa^-1, covering a wide linear working pressure range of 0.06-100 kPa. For its piezoelectric potential, PW-12 shows a sensitivity of 0.443 V·kPa^-1 with ultralow frequency detection as low as 0.0028 Hz, and good cyclability over 60,000 cycles under 0.41 Hz. The nature-derived all-wood pressure sensor shows obvious superiority in the flexibility for power supply requirement. More importantly, it presents fully decoupled signals without cross-talks in the dual-sensing functionality. Sensor like this is capable of monitoring various dynamic human motions, making it an extremely promising candidate for the next generation artificial intelligence products.

Efficient Fabrication of TPU/MXene/Tungsten Disulfide Fibers with Ultra-Fast Response for Human Respiratory Pattern Recognition and Disease Diagnosis via Deep Learning

Flexible wearable pressure sensors have received increasing attention as the potential application of flexible wearable devices in human health monitoring and artificial intelligence. However, the complex and expensive process of the conductive filler has limited its practical production and application on a large scale to a certain extent. This study presents a kind of piezoresistive sensor by sinking nonwoven fabrics (NWFs) into tungsten disulfide (WS2) and Ti3C2Tx MXene solutions. With the advantages of a simple production process and practicality, it is conducive to the realization of large-scale production. The assembled flexible pressure sensor exhibits high sensitivity (45.81 kPa-1), wide detection range (0-410 kPa), fast response/recovery time (18/36 ms), and excellent stability and long-term durability (up to 5000 test cycles). Because of the high elastic modulus of MXene and the synergistic effect between WS2 and MXene, the detection range and sensitivity of the piezoresistive pressure sensor are greatly improved, realizing the stable detection of human motion status in all directions. Meanwhile, its high sensitivity at low pressure allows the sensor to accurately detect weak signals such as weak airflow and wrist pulses. In addition, combining the sensor with deep-learning makes it easy to recognize human respiratory patterns with high accuracy, demonstrating its potential impact in the fields of ergonomics and low-cost flexible electronics.

Recent Advances in Flexible Piezoresistive Arrays: Materials, Design, and Applications

Spatial distribution perception has become an important trend for flexible pressure sensors, which endows wearable health devices, bionic robots, and human-machine interactive interfaces (HMI) with more precise tactile perception capabilities. Flexible pressure sensor arrays can monitor and extract abundant health information to assist in medical detection and diagnosis. Bionic robots and HMI with higher tactile perception abilities will maximize the freedom of human hands. Flexible arrays based on piezoresistive mechanisms have been extensively researched due to the high performance of pressure-sensing properties and simple readout principles. This review summarizes multiple considerations in the design of flexible piezoresistive arrays and recent advances in their development. First, frequently used piezoresistive materials and microstructures are introduced in which various strategies to improve sensor performance are presented. Second, pressure sensor arrays with spatial distribution perception capability are discussed emphatically. Crosstalk is a particular concern for sensor arrays, where mechanical and electrical sources of crosstalk issues and the corresponding solutions are highlighted. Third, several processing methods are also introduced, classified as printing, field-assisted and laser-assisted fabrication. Next, the representative application works of flexible piezoresistive arrays are provided, including human-interactive systems, healthcare devices, and some other scenarios. Finally, outlooks on the development of piezoresistive arrays are given.

Visible-Light Transparent, Ultrastretchable, and Self-Healable Semicrystalline Fluorinated Ionogels for Underwater Strain Sensing

The development of ultrastretchable ionogels with a combination of high transparency and unique waterproofness is central to the development of emerging skin-inspired sensors. In this study, an ultrastretchable semicrystalline fluorinated ionogel (SFIG) with visible-light transparency and underwater stability is prepared through one-pot copolymerization of acrylic acid and fluorinated acrylate monomers in a mixed solution of poly(ethylene oxide) (PEO) and fluorinated ionic liquids. Benefiting from the formation of the PEO-chain semicrystalline microstructures and the abundant noncovalent interactions (reversible hydrogen bonds and ion-dipole interactions) in an ionogel, SFIG is rendered with room-temperature stable cross-linking structures, providing high mechanical elasticity as well as high chain segment dynamics for self-healing and efficient energy absorption during the deformation. The resultant SFIG exhibits excellent stretchability (>2500%), improved mechanical toughness (7.4 MJ m^-3), and room-temperature self-healability. Due to the high compatibility and abundance of hydrophobic fluorinated moieties in the ionogel, the SFIG demonstrates high visible-light transparency (>97%) and excellent waterproofness. Due to these unique advantages, the as-prepared SFIG is capable of working as an ultrastretchable ionic conductor in capacitive-type strain sensors, demonstrating excellent underwater strain-sensing performances with high sensitivity, large detecting range, and exceptional durability. This work might provide a straightforward and efficient method for obtaining waterproof ionogel elastomers for application in next-generation underwater sensors and communications.

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.