Thin and Flexible Carbon Nanotube-Based Pressure Sensors with Ultrawide Sensing Range

Wireless breathable face mask sensor for spatiotemporal 2D respiration profiling and respiratory diagnosis

Owing to air pollution and the pandemic outbreak, the need for quantitative pulmonary monitoring has greatly increased. The COVID-19 outbreak has aroused attention for comfortable wireless monitoring of respiratory profiles and more real-time diagnosis of respiratory diseases. Although respiration sensors have been investigated extensively with single-pixel sensors, 2D respiration profiling with a pixelated array sensor has not been demonstrated for both exhaling and inhaling. Since the pixelated array sensor allowed for simultaneous profiling of the nasal breathing and oral breathing, it provides essential respiratory information such as breathing patterns, respiration habit, breathing disorders. In this study, we introduced an air-permeable, stretchable, and a pixelated pressure sensor that can be integrated into a commercial face mask. The mask sensor showed a strain-independent pressure-sensing performance, providing 2D pressure profiles for exhalation and inhalation. Real-time 2D respiration profiles could monitor various respiratory behaviors, such as oral/nasal breathing, clogged nose, out-of-breath, and coughing. Furthermore, they could detect respiratory diseases, such as rhinitis, sleep apnea, and pneumonia. The 2D respiratory profiling mask sensor is expected to be employed for remote respiration monitoring and timely patient treatment.

An Intelligent Non-Invasive Blood Pressure Monitoring System Based on a Novel Polyvinylidene Fluoride Piezoelectric Thin Film

Hypertension is a common cause of cardiovascular diseases, closely associated with the high mortality and disability rates of cardiovascular diseases such as stroke and coronary heart disease. Therefore, developing a comfortable and sustainable device for monitoring human pulse signals holds practical significance for the prevention and treatment of hypertension and cardiovascular diseases. PVDF flexible pressure sensors possess the characteristics of high sensitivity, good flexibility, and strong biocompatibility, thereby demonstrating extensive application potential in areas such as health monitoring, wearable devices, and electronic skins. This paper focuses on the development of a modified piezoelectric polymer and its application in an intelligent blood pressure monitoring system, demonstrating its outstanding performance and feasibility through a series of experiments. This research provides innovative material choices for the development of intelligent medical devices and offers beneficial guidance for the design and application of future intelligent health monitoring systems.

Flexible Pressure Sensors in Human-Machine Interface Applications

Flexible sensors are highly flexible, malleable, and capable of adapting todifferent shapes, surfaces, and environments, which opens a wide range ofpotential applications in the field of human-machine interface (HMI). Inparticular, flexible pressure sensors as a crucial member of the flexiblesensor family, are widely used in wearable devices, health monitoringinstruments, robots and other fields because they can achieve accuratemeasurement and convert the pressure into electrical signals. The mostintuitive feeling that flexible sensors bring to people is the change ofhuman-machine interface interaction, from the previous rigid interaction suchas keyboard and mouse to flexible interaction such as smart gloves, more inline with people's natural control habits. Many advanced flexible pressuresensors have emerged through extensive research and development, and to adaptto various fields of application. Researchers have been seeking to enhanceperformance of flexible pressure sensors through improving materials, sensingmechanisms, fabrication methods, and microstructures. This paper reviews the flexible pressure sensors in HMI in recent years, mainlyincluding the following aspects: current cutting-edge flexible pressuresensors; sensing mechanisms, substrate materials and active materials; sensorfabrication, performances, and their optimization methods; the flexiblepressure sensors for various HMI applications and their prospects.

High-sensitivity piezoresistive sensors based on cellulose handsheets using origami-inspired corrugated structures

Cellulose-based composites have attracted significant attention in the fabrication and advancement of wearable devices due to their sustainable, degradable, and cost-effective properties. However, achieving a cellulosic sensor with reliable sensory feedback remains challenging owing to the deficiency in reversible microstructures during response processes. In this study, we developed a piezoresistive sensor consisting of nearly pure cellulose handsheets using origami-inspired corrugated structures to achieve durable and sensitive piezoresistive responses. Multi-walled carbon nanotubes (MWCNTs) were used as conducting agents. With the addition of 7 wt% MWCNTs, 36.27 % of the cellulose fiber surface was covered and the conductivity of cellulose handsheets was increased to 8.7 S/m. The obtained conductive cellulose handsheets were transformed into corrugated structures and integrated orthogonally to construct the piezoresistive sensors with reversible electrical paths for electrons. The restorable corrugated structure endowed the sensors with a wide workable pressure range (0-10 kPa), high sensitivity (6.09 kPa-1 in a range of 0-0.92 kPa), fast response time (<280 ms), and good durability (>1000 cycles). Furthermore, the practical applications of the proposed sensors as wearable devices were demonstrated through phonation, real-time sports monitoring, and step pressure tests.

Strong, conductive, and freezing-tolerant polyacrylamide/PEDOT:PSS/cellulose nanofibrils hydrogels for wearable strain sensors

Hydrogels with prominent flexibility, versatility, and high sensitivity play an important role in the design and fabrication of wearable sensors. In particular, these flexible conductive hydrogels exhibit elastic modulus that is highly compatible with human skin, demonstrating the great potential for flexible sensing. However, the preparation of high-performance hydrogel-based sensors that can restrain extreme cold conditions is still challenging. Herein, a novel anti-freezing composite hydrogel with superior conductivity based on polyacrylamide (PAM), LiCl, and PEDOT:PSS coated cellulose nanofibrils (PAM/PEDOT:PSS/CNF) is constructed. The addition of CNF increased the hydrogen bonding sites of the molecular chains in the micro, thus improving the mechanical strength and the conductivity of the hydrogel in the macro. The hydrogels achieve a high tensile strength of 0.19 MPa, compressive strength of 0.92 MPa, and dissipation energy of 41.9 kJ/m³. Otherwise, LiCl increases the interactions between the colloidal phase and water molecules, endowing the hydrogels with excellent freezing tolerance. Specifically, the optimized hydrogel of 45 % LiCl exhibited stable mechanical properties at -40 °C. Finally, the composite hydrogel was used to assemble flexible sensors with high sensitivity of 10.3 MPa^-1, which can detect a wide range of human movements and physiological activities.

Estimating ground reaction force with novel carbon nanotube-based textile insole pressure sensors

This study presents a new wearable insole pressure sensor (IPS), composed of fabric coated in a carbon nanotube-based composite thin film, and validates its use for quantifying ground reaction forces (GRFs) during human walking. Healthy young adults (n = 7) walked on a treadmill at three different speeds while data were recorded simultaneously from the IPS and a force plate (FP). The IPS was compared against the FP by evaluating differences between the two instruments under two different assessments: (1) comparing the two peak forces at weight acceptance and push-off (2PK) and (2) comparing the absolute maximum (MAX) of each gait cycle. Agreement between the two systems was evaluated using the Bland-Altman method. For the 2PK assessment, the group mean of differences (MoD) was -1.3 ± 4.3% body weight (BW) and the distance between the MoD and the limits of agreement (2S) was 25.4 ± 11.1% BW. For the MAX assessment, the average MoD across subjects was 1.9 ± 3.0% BW, and 2S was 15.8 ± 9.3% BW. The results of this study show that this sensor technology can be used to obtain accurate measurements of peak walking forces with a basic calibration and consequently open new opportunities to monitor GRF outside of the laboratory.

Microfluidic techniques for mechanical measurements of biological samples

The use of microfluidics to make mechanical property measurements is increasingly common. Fabrication of microfluidic devices has enabled various types of flow control and sensor integration at micrometer length scales to interrogate biological materials. For rheological measurements of biofluids, the small length scales are well suited to reach high rates, and measurements can be made on droplet-sized samples. The control of flow fields, constrictions, and external fields can be used in microfluidics to make mechanical measurements of individual bioparticle properties, often at high sampling rates for high-throughput measurements. Microfluidics also enables the measurement of bio-surfaces, such as the elasticity and permeability properties of layers of cells cultured in microfluidic devices. Recent progress on these topics is reviewed, and future directions are discussed.

Wearable Two-Dimensional Nanomaterial-Based Flexible Sensors for Blood Pressure Monitoring: A Review

Flexible sensors have been extensively employed in wearable technologies for physiological monitoring given the technological advancement in recent years. Conventional sensors made of silicon or glass substrates may be limited by their rigid structures, bulkiness, and incapability for continuous monitoring of vital signs, such as blood pressure (BP). Two-dimensional (2D) nanomaterials have received considerable attention in the fabrication of flexible sensors due to their large surface-area-to-volume ratio, high electrical conductivity, cost effectiveness, flexibility, and light weight. This review discusses the transduction mechanisms, namely, piezoelectric, capacitive, piezoresistive, and triboelectric, of flexible sensors. Several 2D nanomaterials used as sensing elements for flexible BP sensors are reviewed in terms of their mechanisms, materials, and sensing performance. Previous works on wearable BP sensors are presented, including epidermal patches, electronic tattoos, and commercialized BP patches. Finally, the challenges and future outlook of this emerging technology are addressed for non-invasive and continuous BP monitoring.

PET/ZnO@MXene-Based Flexible Fabrics with Dual Piezoelectric Functions of Compression and Tension

The traditional self-supported piezoelectric thin films prepared by filtration methods are limited in practical applications due to their poor tensile properties. The strategy of using flexible polyethylene terephthalate (PET) fabric as the flexible substrate is beneficial to enhancing the flexibility and stretchability of the flexible device, thus extending the applications of pressure sensors. In this work, a novel wearable pressure sensor is prepared, of which uniform and dense ZnO nanoarray-coated PET fabrics are covered by a two-dimensional MXene nanosheet. The ternary structure incorporates the advantages of the three components including the superior piezoelectric properties of ZnO nanorod arrays, the excellent flexibility of the PET substrate, and the outstanding conductivity of MXene, resulting in a novel wearable sensor with excellent pressure-sensitive properties. The PET/ZnO@MXene pressure sensor exhibits excellent sensing performance (S = 53.22 kPa-1), fast response/recovery speeds (150 ms and 100 ms), and superior flexural stability (over 30 cycles at 5% strain). The composite fabric also shows high sensitivity in both motion monitoring and physiological signal detection (e.g., device bending, elbow bending, finger bending, wrist pulse peaks, and sound signal discrimination). These findings provide insight into composite fabric-based pressure-sensitive materials, demonstrating the great significance and promising prospects in the field of flexible pressure sensing.

Recent Developments and Implementations of Conductive Polymer-Based Flexible Devices in Sensing Applications

Flexible sensing devices have attracted significant attention for various applications, such as medical devices, environmental monitoring, and healthcare. Numerous materials have been used to fabricate flexible sensing devices and improve their sensing performance in terms of their electrical and mechanical properties. Among the studied materials, conductive polymers are promising candidates for next-generation flexible, stretchable, and wearable electronic devices because of their outstanding characteristics, such as flexibility, light weight, and non-toxicity. Understanding the interesting properties of conductive polymers and the solution-based deposition processes and patterning technologies used for conductive polymer device fabrication is necessary to develop appropriate and highly effective flexible sensors. The present review provides scientific evidence for promising strategies for fabricating conductive polymer-based flexible sensors. Specifically, the outstanding nature of the structures, conductivity, and synthesis methods of some of the main conductive polymers are discussed. Furthermore, conventional and innovative technologies for preparing conductive polymer thin films in flexible sensors are identified and evaluated, as are the potential applications of these sensors in environmental and human health monitoring.

Materials, Preparation Strategies, and Wearable Sensor Applications of Conductive Fibers: A Review

The recent advances in wearable sensors and intelligent human-machine interfaces have sparked a great many interests in conductive fibers owing to their high conductivity, light weight, good flexibility, and durability. As one of the most impressive materials for wearable sensors, conductive fibers can be made from a variety of raw sources via diverse preparation strategies. Herein, to offer a comprehensive understanding of conductive fibers, we present an overview of the recent progress in the materials, the preparation strategies, and the wearable sensor applications related. Firstly, the three types of conductive fibers, including metal-based, carbon-based, and polymer-based, are summarized in terms of their principal material composition. Then, various preparation strategies of conductive fibers are established. Next, the primary wearable sensors made of conductive fibers are illustrated in detail. Finally, a robust outlook on conductive fibers and their wearable sensor applications are addressed.

Empirical Study on Human Movement Classification Using Insole Footwear Sensor System and Machine Learning

This paper presents a plantar pressure sensor system (P2S2) integrated in the insoles of shoes to detect thirteen commonly used human movements including walking, stooping left and right, pulling a cart backward, squatting, descending, ascending stairs, running, and falling (front, back, right, left). Six force sensitive resistors (FSR) sensors were positioned on critical pressure points on the insoles to capture the electrical signature of pressure change in the various movements. A total of 34 adult participants were tested with the P2S2. The pressure data were collected and processed using a Principal Component Analysis (PCA) for input to the multiple machine learning (ML) algorithms, including k-NN, neural network and Support-Vector Machine (SVM) algorithms. The ML models were trained using four-fold cross-validation. Each fold kept subject data independent from other folds. The model proved effective with an accuracy of 86%, showing a promising result in predicting human movements using the P2S2 integrated in shoes.

Flexible Stannum-Doped SrTiO3 Nanofiber Membranes for Highly Sensitive and Reliable Piezoresistive Pressure Sensors

Mechanically flexible ceramic fiber-based electronic skins are attractive materials ascribed to the features of monitoring signals of various physical parameters in a harsh environment, but the inherent brittleness of the ceramic fibers has limited their wide applications in emerging fields, such as fire-protecting clothing. Herein, a strategy to fabricate the flexible stannum(IV)-doped SrTiO3 (SSTO) nanofiber membranes by a facile sol-gel electrospinning method is reported. The calcination temperature and Sn4+ doping content play vital roles in regulating the crystalline and pore structures that are closely relevant to the flexibility and mechanical properties of the resultant SSTO nanofiber membranes. The as-prepared SSTO nanofiber membranes exhibited exceptional flexibility with an optimum tensile strength of 0.22 MPa, an elongation rate of 1.8%, and a Young's modulus of 13.3 MPa. Significantly, the flexible SSTO nanofiber-based piezoresistive sensors exhibited intriguing sensing performance toward pressure involving high sensitivity (2.24 kPa-1) in a low-pressure range (<400 Pa), fast response time (12 ms) and recovery time (32 ms), good durability (>1000 cycles), and excellent stability at different humidity levels and elevated temperatures. Furthermore, the sensor can also accurately monitor the signals of human motion such as finger bending, throat swallowing, and radial pulse. The fabrication of flexible ceramic nanofiber-based piezoresistive sensors would pave the way to fabricate wearable devices for fire-protecting clothing, personal healthcare, real-time human activity detection.

Wearable Pressure/Touch Sensors Based on Hybrid Dielectric Composites of Zinc Oxide Nanowires/Poly(dimethylsiloxane) and Flexible Electrodes of Immobilized Carbon Nanotube Random Networks

Capacitive-type physical sensors based on hybrid dielectric composites of zinc oxide nanowires/poly(dimethylsiloxane) (ZnO NWs@PDMS) and flexible electrodes of immobilized carbon nanotube (CNT) random networks, which are highly sensitive to pressure and touch stimuli, are demonstrated. Immobilized CNT random networks densely entangled in a Nafion matrix improve the electrical stability of wearable pressure sensors against mechanical stress with a bending radius of 5 mm. The effect of ZnO NW incorporation into PDMS on the sensing performance of pressure sensors is investigated, which results in a significantly enhanced sensitivity of 8.77 × 10^-4 Pa^-1 in low-pressure regions, compared to pristine PDMS (1.32 × 10^-4 Pa^-1). This improvement is attributed to the increase in the effective dielectric constant (ε_r) of the hybrid dielectric composites with their piezoelectric properties. In addition, wearable pressure/touch sensor arrays capable of detecting ultralow pressures (down to 20 Pa) and the real-time identification of touch and pressure stimuli via different sensing mechanisms are demonstrated. We believe that the multifunctionality introduced by the proposed sensors can extend the potential of physical sensor applications, while they are suitable for integration with wearable electronics based on hybrid nanocomposites and interfaces.

An ultra-broad-range pressure sensor based on a gradient stiffness design

The question of how to make artificial intelligence robots perceive the power of "light as a feather" and "heavy as a mountain" at the same time has always been a goal that people are striving to achieve. However, pressure sensors, the key components of electronic equipment, are often unable to incorporate high sensitivity and wide range performance. Here, we proposed a "gradient stiffness design" strategy to prepare a kind of carbon nanotube sponge with a stiffness difference of up to 254 times between different layers, but still maintaining an integral conductive network without delamination. This gradient stiffness structure sponge shows prominent sensing properties with ultra-broad range (from 0.0022 MPa to 5.47 MPa) and high sensitivity. The low stiffness layer can detect low stress (0.0022 MPa) with high sensitivity of 0.765 MPa^-1, and the high stiffness layer can greatly extend the sensing range to an unprecedentedly high value (5.47 MPa). It can concisely detect various motions with different stress, from slight clamping of fragile fries by the robot fingers to heavily stomping motions by a 90 kg person. Moreover, a series of human movements from small-scale to large-scale can be also monitored, revealing the great potential of this gradient stiffness structure in future sensing research.

A flexible and highly sensitive pressure sensor based on three-dimensional electrospun carbon nanofibers

High-performance flexible pressure sensors with high sensitivity are important components of the systems for healthcare monitoring, human–machine interaction, and electronic skin. Herein, a flexible and highly sensitive pressure sensor composed of ferrosoferric oxide (Fe₃O₄)/carbon nanofibers (FeOCN) was fabricated using three-dimensional electrospinning and further heat treatment methods. The obtained pressure sensor demonstrates a wide working range (0–4.9 kPa) and a high sensitivity of 0.545 kPa⁻¹ as well as an ultralow detection limit of 6 Pa. Additionally, the pressure sensor exhibits a rapid response time, good stability, high hydrophobicity, and excellent flexibility. These merits endow the pressure sensor with the ability to precisely detect wrist pulse, phonation, breathing, and finger bending in real-time. Therefore, the FeOCN pressure sensor presents a promising application in real-time healthcare monitoring.

A three-dimensional electrospun carbon nanofiber network was used to measure press strains with high sensitivity.

Highly Sensitive Porous PDMS-Based Capacitive Pressure Sensors Fabricated on Fabric Platform for Wearable Applications

A novel porous polydimethylsiloxane (PDMS)-based capacitive pressure sensor was fabricated by optimizing the dielectric layer porosity for wide-range pressure sensing applications in the sports field. The pressure sensor consists of a porous PDMS dielectric layer and two fabric-based conductive electrodes. The porous PDMS dielectric layer was fabricated by introducing nitric acid (HNO₃) into a mixture of PDMS and sodium hydrogen bicarbonate (NaHCO₃) to facilitate the liberation of carbon dioxide (CO₂) gas, which induces the creation of porous microstructures within the PDMS dielectric layer. Nine different pressure sensors (PS1, PS2,..., PS9) were fabricated in which the porosity (pore size, thickness) and dielectric constant of the PDMS dielectric layers were varied by changing the curing temperature, the mixing proportions of the HNO₃/PDMS concentration, and the PDMS mixing ratio. The response of the fabricated pressure sensors was investigated for the applied pressures ranging from 0 to 1000 kPa. A relative capacitance change of ∼100, ∼323, and ∼485% was obtained by increasing the curing temperature from 110 to 140 to 170 °C, respectively. Similarly, a relative capacitance change of ∼170, ∼282, and ∼323% was obtained by increasing the HNO₃/PDMS concentration from 10 to 15 to 20%, respectively. In addition, a relative capacitance change of ∼94, ∼323, and ∼460% was obtained by increasing the PDMS elastomer base/curing agent ratio from 5:1 to 10:1 to 15:1, respectively. PS9 exhibited the highest sensitivity over a wide pressure sensing range (low-pressure ranges (<50 Pa), 0.3 kPa^-1; high-pressure ranges (0.2-1 MPa), 3.2 MPa^-1). From the results, it was observed that the pressure sensors with dielectric layers prepared at relatively higher curing temperatures, higher HNO₃ concentrations, and higher PDMS ratios resulted in increased porosity and provided the highest sensitivity. As an application demonstrator, a wearable fit cap was developed using an array of 16 pressure sensors for measuring and mapping the applied pressures on a player's head while wearing a helmet. The pressure mapping aids in observing and understanding the proper fit of the helmet in sports applications.

Mechanical Pressure Characterization of CNT-Graphene Composite Material

Carbon nanotubes (CNTs) and graphene are extensively studied materials in the field of sensing technology and other electronic devices due to their better functional and structural properties. Additionally, more attention is given to utilize these materials as a filler to reinforce the properties of other materials. However, the role of weight percentage of CNTs in the piezoresistive properties of these materials has not been reported yet. In this work, CNT-graphene composite-based piezoresistive pressure samples in the form of pellets with different weight percentages of CNTs were fabricated and characterized. All the samples exhibit a decrease in the direct current (DC) resistance with the increase in external uniaxial applied pressure from 0 to 74.8 kNm⁻². However, under the same external uniaxial applied pressure, the DC resistance exhibit more decrease as the weight percentage of the CNTs increase in the composites.

Electrochemical Synthesis of an Organic Thermoelectric Power Generator

Energy harvesting through residual heat is considered one of the most promising ways to power wearable devices. In this work, thermoelectric textiles were prepared by coating the fabrics, first with multiple-wall carbon nanotubes (MWCNTs) by using the layer-by-layer technique and second with poly(3,4-ethylenedioxythiophene) (PEDOT) deposited by electrochemical polymerization. Sodium deoxycholate and poly(diallyldimethylammonium chloride) were used as stabilizers to prepare the aqueous dispersions of MWCNTs. The electrochemical deposition of PEDOT on the MWCNT-coated fabric was carried out in a three-electrode electrochemical cell. The polymerization of PEDOT on the fabric increased the electrical conductivity by ten orders of magnitude (through the plane), establishing an excellent path for electric transport across the fabrics. In addition, the fibers showed a Seebeck coefficient of 14.3 μV K^-1, which is characteristic of highly doped PEDOT. As a proof of concept, several thermoelectric modules were made with different elements based on the coated acrylic and cotton fabrics. The best generator made of 30 thermoelectric elements using acrylic fabrics exhibited an output power of 0.9 μW with a temperature difference of 31 K.

Sensing-range-tunable pressure sensors realized by self-patterned-spacer design and vertical CNT arrays embedded in PDMS

A pressure sensor design suitable for a broad sensing range with high sensitivity and good stability is highly desirable for the detection of various pressures and meeting the requirements of different applications. Herein, we report sensing-range-tunable piezoresistive pressure sensors realized by self-patterned-spacer design. In the sensors, the two CNT-array layers embedded in PDMS are separated by the proposed self-patterned spacer. With this structure, the realized sensors with large initial resistance designed show tunable response thresholds from 300 Pa to 6.5 kPa while maintaining high sensitivity, which are realized by controlling the spacer thickness and the CNT length. Besides, the vertical CNT arrays have a large specific surface area, which can dramatically change the resistance of the pressure sensors and lead to high sensitivity with nearly 50 kPa^-1. Benefiting from the designs of the self-patterned spacer and the advantageous combination of CNTs and PDMS, the pressure sensors also exhibit a rapid response/relaxation time of 24/32 ms, and good long-term stability with durability test over 10 000 loading/unloading cycles. On the other hand, the realized pressure sensors with small initial resistance designed show a typical piezoresistive characteristic. For applications, the pressure sensors with large initial resistance designed are suitable for the anti-noise applications with pressure thresholds to filter unnecessary noise and save power consumption, while the pressure sensors with small initial resistance designed show the capability of detecting mechanical forces and monitoring human physiological signals. Moreover, the self-patterned design and fabrication method of the spacers also show potentials to be applied in the existing works to further enhance or adjust the performance of those pressure sensors, showing great flexibility. This design demonstrates great potentials to be applied in future advanced flexible wearable systems such as health monitoring, human-machine interaction and the Internet of Things.

Rapid Nanowelding of Carbon Coatings onto Glass Fibers by Electrothermal Shock

With the rapid development of nanomanufacturing, scaling up of nanomaterials requires advanced manufacturing technology to composite nanomaterials with disparate materials (ceramics, metals, and polymers) to achieve hybrid properties and coupling performances for practical applications. Attempts to assemble nanomaterials onto macroscopic materials are often accompanied by the loss of exceptional nanoscale properties during the fabrication process, which is mainly due to the poor contacts between carbon nanomaterials and macroscopic bulk materials. In this work, we proposed a novel cross-scale manufacturing concept to process disparate materials in different length scales and successfully demonstrated an electrothermal shock approach to process the nanoscale material (e.g., carbon nanotubes) and macroscale (e.g., glass fiber) with good bonding and excellent mechanical property for emerging applications. The excellent performance and potentially lower cost of the electrothermal shock technology offers a continuous, ultrafast, energy-efficient, and roll-to-roll process as a promising heating solution for cross-scale manufacturing.

Breathable and Large Curved Area Perceptible Flexible Piezoresistive Sensors Fabricated with Conductive Nanofiber Assemblies

The rapid development of wearable electronics, humanoid robots, and artificial intelligence requires sensors to sensitively and stably detect external stress variations in large areas or on three-dimensional (3D) irregularly shaped surfaces while possessing the comfort. Most importantly, the flexibility and 3D compliance of sensors, and the fitting state of the interface between the sensor and the object are of great significance to the sensing accuracy and reliability. The ordered or random stacking and entangling of flexible and electrically conductive fiber materials can form a highly porous and mechanically stable fiber assembly. The changes in external stress can lead to the air trapped in the fiber assembly to flow in and out rapidly and repeatedly, as well as the reversible mechanical deformation of fiber materials. Correspondingly, the contact areas between electrically conductive fibers in the fiber assembly are reversibly changed, which makes the conductive and flexible fiber assembly be an ideal candidate for piezoresistive sensing material. It can be further expected that the statistical stability of contact points between conductive fibers under the stress may significantly increase with the decrease in fiber diameters. Herein, a new method to make a flexible piezoresistive sensor with conductive and porous fiber assembly was proposed. An ultrasensitive piezoresistive material was facilely prepared by fabricating conductive poly(vinyl alcohol-co-ethylene) (EVOH) nanofiber assemblies. The sensing performance of the piezoresistive sensor was optimized by regulating the nanofiber morphology, electrical conductivity, and mechanical properties. The flexible piezoresistive sensor exhibited a sensitivity of 2.79 kPa^-1, a response time of 3 ms, and a recovery time of 10 ms. The sensing performance at different working frequencies was stable and durable within 4500 cycling tests. The flexible sensor showed good pressure-sensing accuracy and reliability when used on irregular surfaces and therefore was further applied in the static monitoring of large-area spatial pressure distribution and the wearable intelligent interactive device, demonstrating great application potential.

Near-Linear Responsive and Wide-Range Pressure and Stretch Sensor Based on Hierarchical Graphene-Based Structures via Solvent-Free Preparation

Flexible and wearable electronics have huge potential applications in human motion detection, human-computer interaction, and context identification, which have promoted the rapid development of flexible sensors. So far the sensor manufacturing techniques are complex and require a large number of organic solvents, which are harmful not only to human health but also to the environment. Here, we propose a facile solvent-free preparation toward a flexible pressure and stretch sensor based on a hierarchical layer of graphene nanoplates. The resulting sensor exhibits many merits, including near-linear response, low strain detection limits to 0.1%, large strain gauge factor up to 36.2, and excellent cyclic stability withstanding more than 1000 cycles. Besides, the sensor has an extraordinary pressure range as large as 700 kPa. Compared to most of the reported graphene-based sensors, this work uses a completely environmental-friendly method that does not contain any organic solvents. Moreover, the sensor can practically realize the delicate detection of human body activity, speech recognition, and handwriting recognition, demonstrating a huge potential for wearable sensors.

Design and Initial Testing of an Affordable and Accessible Smart Compression Garment to Measure Physical Activity Using Conductive Paint Stretch Sensors

Motion capture and the measurement of physical activity are common practices in the fields of physical therapy, sports medicine, biomechanics, and kinesiology. The data collected by these systems can be very important to understand how someone is recovering or how effective various assistive devices may be. Traditional motion capture systems are very expensive and only allow for data collection to be performed in a lab environment. In our previous research, we have tested the validity of a novel stitched stretch sensor using conductive thread. This paper furthers that research by validating a smart compression garment with integrated conductive paint stretch sensors to measure movement. These sensors are very inexpensive to fabricate and, when paired with an open-sourced wireless microcontroller, can enable a more affordable, accessible, and comfortable form of motion capture. A wearable garment like the one tested in this study could allow us to understand how meaningful, functional activities are performed in a natural setting.

Flexible and Stretchable Temperature Sensors Fabricated Using Solution-Processable Conductive Polymer Composites

Accurate monitoring of physiological temperatures is important for the diagnosis and tracking of various medical conditions. This work presents the design, fabrication, and characterization of temperature sensors using conductive polymer composites (CPCs) patterned on both flexible and stretchable substrates through both drop coating and direct ink writing (DIW). These composites were formed using a high melting point biopolymer polyhydroxybutyrate (PHB) as the matrix and the graphenic nanomaterial reduced graphene oxide (rGO) as the nanofiller (from 3 to 12 wt%), resulting in a material that exhibits a temperature-dependent resistivity. At room temperature the composites exhibited electrical percolation behavior. Around the percolation threshold, both the carrier concentration and mobility were found to increase sharply. Sensors were fabricated by drop-coating PHB-rGO composites onto ink-jet printed silver electrodes. The temperature coefficient of resistance was determined to be 0.018 /°C for pressed rGO powders and 0.008 /°C for the 3 wt% samples (the highest responsivity of all composites). Composites were found to have good selectivity to temperature with respect to pressure and moisture. Thermal mapping was demonstrated using 6 × 7 arrays of sensing elements. Stretchable devices with a meandering pattern were fabricated using DIW, demonstrating the potential for these materials in healthcare monitoring devices.

Super Tough and Self-Healable Poly(dimethylsiloxane) Elastomer via Hydrogen Bonding Association and Its Applications as Triboelectric Nanogenerators

Poly(dimethylsiloxane) (PDMS) as one of the electron-drawing materials has been widely used in triboelectric nanogenerators (TENG), which is expected to generate electron through friction and required to endure dynamic loads. However, the nature of the siloxane bond and the low interchain interaction between the methyl side groups result in low fracture energy in PDMS elastomers. Here, a strategy that combined the advantages of the dynamic of hierarchical hydrogen bonding and phase-separation-like structure was adopted to improve the toughness of PDMS elastomers. By varying both stronger and weaker hydrogen bonding within the PDMS network, a series of super tough (up to 24,000 J/m²), notch-insensitive, transparent, and autonomous self-healable elastomers were achieved. In addition, a hydrophilic polymeric material (PDMAS-U10) was synthesized as the conductive layer. A transparent TENG was fabricated by sandwiching the PDMAS-U10 between two pieces of the PDMS elastomer. Despite its hydrophilic nature, PDMAS-U10 exhibit strong adhesion interaction with hydrophobic PDMS elastomers. As such, a tough (16,500 J/m²), self-healable (efficiency ∼97%), and transparent triboelectric nanogenerator was constructed. A self-powered system employing the TENG is also demonstrated in this work.

Hierarchical Composites with Electrophoretically Deposited Carbon Nanotubes for In Situ Sensing of Deformation and Damage

As composites are used increasingly in structural components, novel techniques for detecting micro-scale damage are required. Their nanoscale size and high aspect ratio allow carbon nanotubes to create electrically conductive pathways that enable sensing. In this work, carbon nanotubes are deposited onto glass fabric using electrophoretic deposition to create hierarchical composites. Polyethylenimine functionalized carbon nanotubes are deposited from an aqueous dispersion using an electric field. Symmetric cross-ply composites are investigated as a model system to demonstrate the ability to detect incipient damage and transverse microcracks. The specimens are subjected to tensile loading, and a resistance increase is observed because of two key mechanisms-a reversible change in nanotube-nanotube tunneling gaps due to elastic straining of the network and a permanent severing of paths in the conducting network due to formation of transverse cracks in the 90° plies. By analyzing the electrical response, the damage state can be identified. Acoustic emission sensors are used to validate the results. The strength and Young's modulus of the composites with integrated carbon nanotubes are similar to the control specimens. Crack density measurements using edge replication reveal that transverse cracking can be suppressed, demonstrating multi-functionality with improved damage tolerance and integrated sensing.

Textile-Only Capacitive Sensors with a Lockstitch Structure for Facile Integration in Any Areas of a Fabric

A woven structure has been gradually applied in capacitive pressure sensing due to its good performance for fabric integration. However, restricted by the square-cross arrangement of yarns, the woven structure sensors are typically limited to being implemented in rather rectangular areas of a fabric. For nonrectangular areas, a lockstitch structure is shown to be excellent for preparing textile-only capacitive sensors which are based on the conductive core-spun yarns. The lockstitch structure, which is inspired by the stitch type used for sewing, ensures the facile integration of the sensors on the fabric of interest at any position by sewing. The sensors with this novel approach only occupy small spaces, and hence will not affect the overall softness of the fabric at large. Importantly, they show good performance in signaling, sensitivity, stability, and robustness.

Ultrathin Nanofibrous Membranes Containing Insulating Microbeads for Highly Sensitive Flexible Pressure Sensors

Highly sensitive and flexible pressure sensors were developed based on dielectric membranes composed of insulating microbeads contained within polyvinylidene fluoride (PVDF) nanofibers. The membrane is fabricated using a simple electrospinning process. The presence of the microbeads enhances porosity, which in turn enhances the sensitivity (1.12 kPa^-1 for the range of 0-1 kPa) of the membrane when used as a pressure sensor. The microbeads are fixed in position and uniformly distributed throughout the nanofibers, resulting in a wide dynamic range (up to 40 kPa) without any sensitivity loss. The fluffy and nonsticky PVDF nanofiber features low hysteresis and ultrafast response times (∼10 ms). The sensor has also demonstrated reliable pressure detection over 10 000 loading cycles and 250 bending cycles at a 13 mm bending radius. These pressure sensors were successfully applied to detect heart rate and respiratory signals, and an array of sensors was fabricated and used to recognize spatial pressure distribution. The sensors described herein are ultrathin and ultralight, with a total thickness of less than 100 μm, including the electrodes. All of the materials comprising the sensors are flexible, making them suitable for on-body applications such as tactile sensors, electronic skins, and wearable healthcare devices.

Large-Area Carbon Nanotube-Based Flexible Composites for Ultra-Wide Range Pressure Sensing and Spatial Pressure Mapping

Flexible pressure sensors are of broad interest for applications including human-machine interfaces, wearable electronics, and object/motion detection. However, complexities associated with constituent materials, fabrication processes, sensing mechanisms, and hardwiring often hinder the large-scale applications of using high performance pressure sensors reported in the literature. Here we demonstrate a large-area, highly flexible, conformable, and mechanically robust pressure sensor using a silicone elastomer with an embedded nonwoven textile carrier coated with carbon nanotubes. The selected silicone polymer allows through-thickness deformability of the sensor while the high modulus textile carrier ensures in-plane stiffness and stability. The sensor has an initial electrical conductivity of 4.4 ± 0.38 S/m and is fabricated using a straightforward dip coating and polymer infusion process and can be easily scaled-up for large-scale applications. On the basis of its hierarchical composite structure, this piezoresistive pressure sensor possesses extremely high resilience under compression, a repeatable monotonic positive pressure correlation, and an ultrawide elastic working range (5.5 ± 0.5 MPa) that can be segmentally linearized. A true two-dimensional modality for spatial pressure mapping is realized by utilizing electrical impedance tomography (EIT) and demonstrated to yield conductivity maps that can estimate the location, shape, and amplitude of both localized and distributed pressure with simple contact areas.

Highly Stretchable, Directionally Oriented Carbon Nanotube/PDMS Conductive Films with Enhanced Sensitivity as Wearable Strain Sensors

Recent interest in the fields of human motion monitoring, electronic skin, and human-machine interface technology demands strain sensors with high stretchability/compressibility (ε > 50%), high sensitivity (or gauge factor (GF > 100)), and long-lasting electromechanical compliance. However, current metal- and semiconductor-based strain sensors have very low (ε < 5%) stretchability or low sensitivity (GF < 2), typically sacrificing the stretchability for high sensitivity. Composite elastomer sensors are a solution where the challenge is to improve the sensitivity to GF > 100. We propose a simple, low-cost fabrication of mechanically compliant, physically robust metallic carbon nanotube (CNT)-polydimethylsiloxane (PDMS) strain sensors. The process allows the alignment of CNTs within the PDMS elastomer, permitting directional sensing. Aligning CNTs horizontally (HA-CNTs) on the substrate before embedding in the PDMS reduces the number of CNT junctions and introduces scale-like features on the CNT film perpendicular to the tensile strain direction, resulting in improved sensitivity compared to vertically-aligned CNT-(VA-CNT)-PDMS strain sensors under tension. The CNT alignment and the scale-like features modulate the electron conduction pathway, affecting the electrical sensitivity. Resulting GF values are 594 at 15% and 65 at 50% strains for HA-CNT-PDMS and 326 at 25% and 52 at 50% strains for VA-CNT-PDMS sensors. Under compression, VA-CNT-PDMS sensors show more sensitivity to small-scale deformation than HA-CNT-PDMS sensors due to the CNT orientation and the continuous morphology of the film, demonstrating that the sensing ability can be improved by aligning the CNTs in certain directions. Furthermore, mechanical robustness and electromechanical durability are tested for over 6000 cycles up to 50% tensile and compressive strains, with good frequency responses with negligible hysteresis. Finally, both types of sensors are shown to detect small-scale human motions, successfully distinguishing various human motions with reaction and recovery times of as low as 130 ms and 0.5 s, respectively.

Ultrawide Sensing Range and Highly Sensitive Flexible Pressure Sensor Based on a Percolative Thin Film with a Knoll-like Microstructured Surface

Flexible pressure sensors have attracted considerable research interest and efforts owing to their broad application prospects in wearable devices, health monitoring, and human-machine interfacing. High-sensitivity, wide-workable-range, and low-cost pressure sensors are the primary requirement in practical application. In this work, flexible pressure sensors with high sensitivity in a wide pressure range are constructed by introducing a knoll-like microstructured surface into a percolative thermoplastic polyurethane/carbon black sensitive film, using a facile, efficient, and cost-effective screen-printing route. The prepared pressure sensors exhibit an ultrawide sensing pressure range of 0-1500 kPa, high sensitivity (5.205 kPa^-1 in the range of 0-100 kPa and 0.63 kPa^-1 over 1200 kPa), fast response, and excellent durability for more than 30 000 cycles. We demonstrated the applications of our pressure sensors in health monitoring, such as detection of wrist radial artery pulse waves, phonation, and vibrations. In addition, the proposed sensors showed the potential in object manipulation and human-machine interfacing, capable of detecting spatial pressure distribution, measuring grip forces, and monitoring gas pressures.

Electrically Conductive Coatings for Fiber-Based E-Textiles

With the advent of wearable electronic devices in our daily lives, there is a need for soft, flexible, and conformable devices that can provide electronic capabilities without sacrificing comfort. Electronic textiles (e-textiles) combine electronic capabilities of devices such as sensors, actuators, energy harvesting and storage devices, and communication devices with the comfort and conformability of conventional textiles. An important method to fabricate such devices is by coating conventionally used fibers and yarns with electrically conductive materials to create flexible capacitors, resistors, transistors, batteries, and circuits. Textiles constitute an obvious choice for deployment of such flexible electronic components due to their inherent conformability, strength, and stability. Coating a layer of electrically conducting material onto the textile can impart electronic capabilities to the base material in a facile manner. Such a coating can be done at any of the hierarchical levels of the textile structure, i.e., at the fiber, yarn, or fabric level. This review focuses on various electrically conducting materials and methods used for coating e-textile devices, as well as the different configurations that can be obtained from such coatings, creating a smart textile-based system.

Recent Developments for Flexible Pressure Sensors: A Review

Flexible pressure sensors are attracting great interest from researchers and are widely applied in various new electronic equipment because of their distinct characteristics with high flexibility, high sensitivity, and light weight; examples include electronic skin (E-skin) and wearable flexible sensing devices. This review summarizes the research progress of flexible pressure sensors, including three kinds of transduction mechanisms and their respective research developments, and applications in the fields of E-skin and wearable devices. Furthermore, the challenges and development trends of E-skin and wearable flexible sensors are also briefly discussed. Challenges of developing high extensibility, high sensitivity, and flexible multi-function equipment still exist at present. Exploring new sensing mechanisms, seeking new functional materials, and developing novel integration technology of flexible devices will be the key directions in the sensors field in future.

Directly drawing high-performance capacitive sensors on copying tissues

We report here a facile, green and cost-effective fabrication of high-performance capacitive pressure sensors by drawing loop-and disc-shaped graphite electrode arrays on copying tissues. Graphene oxide enhanced foam-like paper is prepared as an efficient dielectric layer. The paper-based capacitive pressure sensor enables sensitive detection of finger touch, motion and proximity.