Facile and Low-Cost Route for Sensitive Stretchable Sensors by Controlling Kinetic and Thermodynamic Conductive Network Regulating Strategies

Printed Directional Bending Sensor with High Sensitivity and Low Hysteresis for Human Motion Detection and Soft Robotic Perception

We present a high-performance flexible bending strain sensor for directional motion detection of human hands and soft robotic grippers. The sensor was fabricated using a printable porous conductive composite composed of polydimethylsiloxane (PDMS) and carbon black (CB). The utilization of a deep eutectic solvent (DES) in the ink formulation induced a phase segregation between the CB and PDMS and led to a porous structure inside the printed films after being vapored. This simple and spontaneously formed conductive architecture provided superior directional bend-sensing characteristics compared to conventional random composites. The resulting flexible bending sensors displayed high bidirectional sensitivity (gauge factor of 45.6 under compressive bending and 35.2 under tensile bending), negligible hysteresis, good linearity (>0.99), and excellent bending durability (over 10,000 cycles). The multifunctional applications of these sensors, including human motion detection, object-shape monitoring, and robotic perceptions, are demonstrated as a proof-of-concept.

Durability Study of Thermal Transfer Printed Textile Electrodes for Wearable Electronic Applications

Textile-based electronics hold great promise because they can endow wearable devices with soft and comfortable characteristics. However, the inherent porosity and fluffiness of fabrics result in high surface roughness, which presents great challenges in the manufacture of high-performance fabric electrodes. In this work, we propose a thermal transfer printing method to address the above challenges, in which electrodes or circuits of silver flake/thermoplastic polyurethane (TPU) composites are prefabricated on a release film by coating and laser engraving and then laminated by hot-pressing to a variety of fabrics and textiles. This universal and scalable production technique enables fabric electrodes to be made without compromising the original wearability, washability, and stretchability of textiles. The prepared fabric electrodes exhibit high conductivity (5.48 × 10⁴ S/cm), high adhesion (≥1750 N/m), good abrasion/washing resistance, high patterning resolution (∼40 μm), and good electromechanical performance up to 50% strain. To demonstrate the potential applications, we developed textile-based radio frequency identification (RFID) tags for remote identification and a large-sized heater for wearable thermotherapy. More importantly, the solvent-free thermal transfer printing technology developed in this paper enables people to DIY interesting flexible electronics on clothes with daily tools, which can promote the commercial application of smart textile-based electronics.

"Toolbox" for the Processing of Functional Polymer Composites

The processing methods of functional polymer composites (FPCs) are systematically summarized in “Toolbox”. The relationship of processing method-structure-property is discussed and the selection and combination of tools in processing among different FPCs are analyzed. A promising prospect is provided regarding the design principle for high performance FPCs for further investigation.

ABSTRACT

Functional polymer composites (FPCs) have attracted increasing attention in recent decades due to their great potential in delivering a wide range of functionalities. These functionalities are largely determined by functional fillers and their network morphology in polymer matrix. In recent years, a large number of studies on morphology control and interfacial modification have been reported, where numerous preparation methods and exciting performance of FPCs have been reported. Despite the fact that these FPCs have many similarities because they are all consisting of functional inorganic fillers and polymer matrices, review on the overall progress of FPCs is still missing, and especially the overall processing strategy for these composites is urgently needed. Herein, a “Toolbox” for the processing of FPCs is proposed to summarize and analyze the overall processing strategies and corresponding morphology evolution for FPCs. From this perspective, the morphological control methods already utilized for various FPCs are systematically reviewed, so that guidelines or even predictions on the processing strategies of various FPCs as well as multi-functional polymer composites could be given. This review should be able to provide interesting insights for the field of FPCs and boost future intelligent design of various FPCs. [Image: see text]

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s40820-021-00774-5.

Aligned wave-like elastomer fibers with robust conductive layers via electroless deposition for stretchable electrode applications

Flexible wearable electronics play an important role in the healthcare industry due to their unique skin affinity, portability and breathability. Despite great progress, it still remains a big challenge to facilely fabricate stretchable electrodes with low resistance, excellent stability and a wide tensile range. Here, we propose a handy and time-saving strategy for the fabrication of elastomeric films consisting of wave-like fibers with a robust conductive layer of silver nanoparticles (AgNPs) immobilized using polydopamine (PDA) and silicone rubber (SR). To realize better stretchability, electrospun thermoplastic polyurethane (TPU) mats with oriented nanofibers were treated via ethanol to achieve a wavy structure, which also allowed for the decoration of AgNP precursors on the TPU surface via PDA assisted electroless deposition (ELD). Therefore, the electrodes achieved a stretchability of 120% with high electrical conductivity (486 S cm^-1). The films with a reduction time of 30 min showed superior electrical conductivity indicated by a resistance increase of only 100% within 50% strain. The TPU/PDA/AgNP/SR composites with a shorter reduction time of silver precursors could monitor human motions as wearable strain sensors with a wide work strain range (0-98%) and a high sensitivity (with a gauge factor (GF) of up to 81.76) for a strain of 80-98%. Therefore, they are an excellent candidate for potential application in prospective stretchable electronics.

Breathable Strain/Temperature Sensor Based on Fibrous Networks of Ionogels Capable of Monitoring Human Motion, Respiration, and Proximity

Wearable strain and temperature sensors are desired for human-machine interfaces, health monitoring, and human motion monitoring. Herein, the fibrous mat with aligned nanofibers of ionic liquid (IL)/thermoplastic polyurethane (TPU) ionogels is fabricated via an electrospinning technique. The resultant fibrous mat is cut into a rectangle specimen and electrodes are loaded along the direction perpendicular to the nanofiber orientation to design a high-performance multimodal sensor based on an ionic conducting mechanism. As a strain sensor, the obtained sensor exhibits a wide strain working range (0-200%), a fast response and recovery (119 ms), a low detection limit (0.1%), and good reproducibility because of the reversible and deformable ionic conductive pathways of the sensor. Moreover, the sensor also exhibits excellent temperature-sensing behaviors, including a monotonic thermal response, high sensitivity (2.75% °C^-1), high accuracy (0.1 °C), a fast response time (2.46 s), and remarkable repeatability, attributable to the negative temperature coefficient behavior of the IL/TPU fibrous mat. More interestingly, the IL/TPU fibrous sensor possesses good breathability, which is desired for wearable electronics. Because of these excellent sensing capabilities in strain and temperature, the sensor can not only monitor tiny and large human motions but also detect respiration and proximity, exhibiting enormous potential in wearable electronics.

Self-Healing, Self-Adhesive Strain Sensors Made with Carbon Nanotubes/Polysiloxanes Based on Unsaturated Carboxyl-Amine Ionic Interactions

Strain sensors with high sensitivity, long-term durability, and stretchability are required for flexible and wearable electronic devices. This paper reports a bilayer strain sensor consisting of carboxyl-functionalized carbon nanotubes (CNTs) and ionically crosslinked polysiloxane substrates based on unsaturated acid-amine interactions. Vacuum filtration was adopted to prepare the CNT films (2.74-4.70 μm in thickness) onto the polysiloxane substrates to prepare stretchable conductive strain sensors. The strain sensor exhibited self-healing ability, self-adhesiveness, high sensitivity, linearity, low hysteresis, and long-term durability with a gauge factor of 33.99 at 55% strain. The sensitivity and linearity could be adjusted by the thickness of the CNT layer. A crack-related mechanism was proposed in which increasing the thickness of the CNT layer led to simultaneously enhanced sensitivity and linearity. Finally, we investigated the detection of human activities (bending/unbending of fingers or knees) and subtle motions (coughing and swallowing). The fabricated strain sensor succeeded in meeting various needs with satisfactory sensing performance.

Highly Tunable Piezoresistive Behavior of Carbon Nanotube-Containing Conductive Polymer Blend Composites Prepared from Two Polymers Exhibiting Crystallization-Induced Phase Separation

Conductive polymer composites (CPCs) are suitable as piezoresistive-sensing materials. When using CPCs for strain sensing, it is still a big challenge to simultaneously improve the piezoresistive sensitivity and linearity along with the electrical conductivity and mechanical properties. Here, highly tunable piezoresistive behavior is reported for multiwalled carbon nanotube (CNT)-filled CPCs based on blends of two semicrystalline polymers poly(vinylidene fluoride) (PVDF) and poly(butylene succinate) (PBS), which are miscible in the melt. When cooling the homogeneous mixture of the blend components, successive crystallization of PVDF and PBS occurs, creating complex crystalline structures in a mixed amorphous phase. The morphology of the blend matrix, the crystallinity of the blend components, and the dispersion and location of the CNTs in the blend depend on the CNT content and the blend composition. Compared with PVDF/CNT composites, the substitution of 10 to 50 wt % PVDF by PBS in the composites shifts the electrical percolation concentration Φ_c from 0.79 wt % to filler contents as low as 0.50 wt % while improving the stretchability. The piezoresistive behavior is highly tunable by changing the PVDF/PBS ratio. The ternary composites with matrix compositions of PVDF (90 wt %)/PBS (10 wt %) and PVDF (50 wt %)/PBS (50 wt %) show either higher piezoresistive sensitivity or linearity, respectively, caused by the differences in the microstructure of the CPCs. For example, the crystallinity of PBS in the ternary composites increased from 19.8% to 52.0% as the PBS content increased from 10 wt % to 50 wt %, which is connected with altered CNT distribution and conductive network structure and substantial improvement of the linearity of the electrical response to strains up to >20%. Our findings highly contribute to the understanding of the piezoresistive properties of CPCs based on two semicrystalline polymers and are important for future studies to tune the piezoresistive behavior to achieve simultaneously improved sensitivity and linearity.

Effect of the Elastomer Matrix on Thermoplastic Elastomer-Based Strain Sensor Fiber Composites

In this study, a thermoplastic elastomer sensor fiber was embedded in an elastomer matrix. The effect of the matrix material on the sensor properties and the piezoresistive behavior of the single fiber-matrix composite system was investigated. For all composites, cycling test (dynamic test) and the relaxation behavior at different strains (quasi-static test) were investigated. In all cases, dynamic properties and quasi-static significantly changed after embedding, compared to the pure fiber. The composite with the silicone elastomer PDMS (Polydimethylsiloxane) as matrix material exhibited deviation from linear response of the resistivity at low strains and proved an unsuitable choice compared to natural rubber. The addition of a spring construct in the embedded sensor fiber natural rubber composite improved the linearity at low strains but increased the mechanical and electrical hysteresis of the soft matter sensor composite. Using pre-vulcanized natural rubber improved linearity at low strains and reduced significantly the stress and relative resistance relaxation as well as the resistance hysteresis, especially if the resistance remained low. In both cases of the pre-vulcanized rubber and the spring structure, the piezoresistive behavior was improved, and at the same time, the stiffness of the system was increased indicating that using a stiffer matrix can be a strategy for improving the sensor properties.

Evaluation of Thermal Properties of 3D Spacer Technical Materials in Cold Environments using 3D Printing Technology

Novel materials have been recently developed for coping with various environmental factors. Generally, to improve the thermal comfort to humans in cold environments, securing an air layer is important. Therefore, this study analyzed the thermal properties of 3D spacer technical materials, 3D printed using thermoplastic polyurethane, according to the structural changes. Four 3D spacer technical material structures were designed with varying pore size and thickness. These samples were moved into a cold climate chamber (temperature 5 ± 1 °C, relative humidity (60 ± 5)%, wind velocity ≤0.2 m/s) and placed on a heating plate set to 30 °C. The surface and internal temperatures were measured after 0, 10, 20, and 30 min and then 10 min after turning off the heating plate. When heat was continuously supplied, the 3D spacer technical material with large pores and a thick air layer showed superior insulation among the materials. However, when no heat was supplied, the air gap thickness dominantly affected thermal insulation, regardless of the pore size. Hence, increasing the air gap is more beneficial than increasing the pore size. Notably, we found that the air gap can increase insulation efficiency, which is of importance to the new concept of 3D printing an interlining.

Piezoresistive Behaviour of Additively Manufactured Multi-Walled Carbon Nanotube/Thermoplastic Polyurethane Nanocomposites

To develop highly sensitive flexible pressure sensors, the mechanical and piezoresistive properties of conductive thermoplastic materials produced via additive manufacturing technology were investigated. Multi-walled carbon nanotubes (MWCNTs) dispersed in thermoplastic polyurethane (TPU), which is flexible and pliable, were used to form filaments. Specimens of the MWCNT/TPU composite with various MWCNT concentrations were printed using fused deposition modelling. Uniaxial tensile tests were conducted, while the mechanical and piezoresistive properties of the MWCNT/TPU composites were measured. To predict the piezoresistive behaviour of the composites, a microscale 3D resistance network model was developed. In addition, a continuum piezoresistive model was proposed for large-scale simulations.

Shape Memory Behavior of Carbon Black-reinforced Trans-1,4-polyisoprene and Low-density Polyethylene Composites

Shape memory composites of trans-1,4-polyisoprene (TPI) and low-density polyethylene (LDPE) with easily achievable transition temperatures were prepared by a simple physical blending method. Carbon black (CB) was introduced to improve the mechanical properties of the TPI/LDPE composites. The mechanical, cure, thermal and shape memory properties of the TPI/LDPE/CB composites were investigated in this study. In these composites, the crosslinked network generated in both the TPI and LDPE portions acted as a fixed domain, while the crystalline regions of the TPI and LDPE portions acted as a reversible domain in shape memory behavior. We found the mechanical properties of composites were promoted significantly with an increase of CB content, accompanied with the deterioration of shape memory properties of composites. When CB dosage was 5 parts per hundred of rubber composites (phr), best shape memory property of composites was obtained with a shape fixity ratio of 95.1% and a shape recovery ratio of 95.0%.

Graphene-Coated Spandex Sensors Embedded into Silicone Sheath for Composites Health Monitoring and Wearable Applications

This study presents a low-cost, tunable, and stretchable sensor fabricated based on spandex (SpX) yarns coated with graphene nanoplatelets (GnP) through a dip-coating process. The SpX/GnP is wrapped into a stretchable silicone rubber (SR) sheath to protect the conductive layer against harsh conditions, which allows for fabricating washable wearable sensors. Dip-coating parameters are optimized to obtain the maximum GnP coating rate. The covering sheath is tailored to achieve high stretchability beyond the sensing limit of 104% for SpX/GnP/SR sensors. Adjustable sensitivity is attained by manipulating SpX immersion times broadening its application for a wide range of strains: Gauge factors as high as two orders of magnitude are achieved at tensile strains greater than ≈40%. The fabricated sensors are tested for two applications: First, the SpX/GnP sensors are integrated into composite fabrics (with no negative impact on the structural integrity of the part) for screening the yarn displacements, resin flow, solidification during the hot press forming process, and structural health monitoring under mechanical loads with minimal cross-sensitivity to temperature/humidity. Second, the capability of SpX/GnP/SP sensors in detection of a wide range of bodily motions (from the joint motion to arterial blood pressure) is demonstrated.

Effect of Matrix and Graphite Filler on Thermal Conductivity of Industrially Feasible Injection Molded Thermoplastic Composites

To understand how the thermal conductivity (TC) of virgin commercial polymers and their composites with low graphite filler amounts can be improved, the effect of material choice, annealing and moisture content is investigated, all with feasible industrial applicability in mind focusing on injection molding. Comparison of commercial HDPE, PP, PLA, ABS, PS, and PA6 based composites under conditions minimizing the effect of the skin-core layer (measurement at half the sample thickness) allows to deduce that at 20 m% of filler, both the (overall) in- and through-plane TC can be significantly improved. The most promising results are for HDPE and PA6 (through/in-plane TC near 0.7/4.3 W·m-1K-1 for HDPE and 0.47/4.3 W·m-1K-1 for PA6 or an increase of 50/825% and 45/1200% respectively, compared to the virgin polymer). Testing with annealed and nucleated PA6 and PLA samples shows that further increasing the crystallinity has a limited effect. A variation of the average molar mass and moisture content is also almost without impact. Intriguingly, the variation of the measuring depth allows to control the relative importance of the TC of the core and skin layer. An increased measurement depth, hence, a higher core-to-skin ratio measurement specifically indicates a clear increase in the through-plane TC (e.g., factor 2). Therefore, for basic shapes, the removal of the skin layer is recommendable to increase the TC.

Pd Nanoparticle Film on a Polymer Substrate for Transparent and Flexible Hydrogen Sensors

Alongside the rise in fully automated equipment and wearable devices, there is currently a high demand for optically transparent and flexible gas sensors operating at room temperature. Nanoparticle films are ideal H₂-sensing materials that can be coupled with flexible substrates because of their discrete nanogranular structure and unique interparticle electrical responsiveness. In this work, we present an optically transparent and flexible H₂ sensor based on a Pd nanoparticle film, prepared on a polyethylene terephthalate sheet using a straightforward nanocluster deposition technique. Hundreds of bending cycles demonstrated that the sensor has good electrical stability and mechanical robustness without significant degradation in H₂-sensing performance. The H₂-sensing behaviors under bent state were systematically evaluated. The loading of tensile and compressive strains under bent state produced a positive and negative influence, respectively, on the sensing performances. The possible influence mechanism of the tensile and compressive strains on the H₂-sensing performance was attributed to the changes in the percolation network topology and the interparticle space induced by the strains. The ability to detect a H₂ concentration as low as 15 ppm, dynamic response range as wide as 0-10%, and sub-10 s response time was achieved. In addition, the sensor can be operated in the relative humidity range of 0-90% at room temperature. These results demonstrate that the sensor exhibits significant potential for next-generation transparent and flexible H₂ detectors.

Mechanical, Thermal, and Shape Memory Properties of Three-Dimensional Printing Biomass Composites

In this study, a series of heat-induced shape memory composites was prepared by the hot-melt extrusion and three-dimensional (3D) printing of thermoplastic polyurethane (TPU) using wood flour (WF) with different contents of EPDM-g-MAH. The mechanical properties, microtopography, thermal property analysis, and heat-induced shape memory properties of the composites were examined. The results showed that, when the EPDM-g-MAH content was 4%, the tensile elongation and tensile strength of the composites reached the maximum value. The scanning electron microscopy and dynamic mechanical analysis results revealed a good interface bonding between TPU and WF when the EPDM-g-MAH content was 4%. The thermogravimetric analysis indicated that the thermal stability of TPU/WF composites was enhanced by the addition of 4% EPDM-g-MAH. Heat-induced shape memory test results showed that the shape memory performance of composites with 4% EPDM-g-MAH was better than that of unmodified-composites. The composites' shape recovery performance at a temperature of 60 °C was higher than that of the composites at ambient temperature. It was also found that, when the filling angle of the specimen was 45°, the recovery angle of the composites was larger.

Ultrastretchable Multilayered Fiber with a Hollow-Monolith Structure for High-Performance Strain Sensor

As a crucial component of data terminal acquisition devices, flexible strain sensor has shown promising applications in numerous fields, such as healthcare, bodynet, the intelligent traffic system, and the robotic system. For stretchable strain sensor, it remains a huge challenge to realize a fine balance of wide detection range and high sensitivity. Here, an electrically conductive carbon nanotube/thermoplastic polyurethane fiber with a multilayered, hollow, and monolith structure, accompanying high stretchability (up to 476% strain) and low density (about 0.46 g/cm³) is fabricated through a facile coaxial wet-spun assembly strategy. The as-prepared fibers with a designed independent sensitive zone and flexible supporting zone possess an ultralow percolation threshold (0.17 wt %) and a tunable size and structure. This structure endows the fiber with a good integration of adequate flexibility, suitable strength, and high elongation at break for wearable electronics. The fiber, which is then assembled as a strain sensor, realizes the perfect combination of the wide sensing range (>350% strain), high sensitivity (gauge factor (GF) = 166.7 at 350% strain), and excellent working durability (>10 000 cycles). Our sensor could also detect small compressing deformations (0.35% N^-1 at 0.025-50 N) by capturing the resistance change of the fiber with superior stability. The highly stretchable, light weight, and multilayered fiber with the designed hollow-monolith structure provides a new route for the preparation of high-performance wearable electronics.