Graphene-coated polymer foams as tuneable impact sensors

Piezoresistive Behavior of a Conductive Polyurethane Based-Foam for Real-Time Structural Monitoring

Smart flexible materials with piezoresistive property are increasingly used in the field of sensors. When embedded in structures, they would allow for in situ structural health monitoring and damage assessment of impact loading, such as crash, bird strikes and ballistic impacts; however, this could not be achieved without a deep characterization of the relation between piezoresistivity and mechanical behavior. The aim of this paper is to study the potential use of the piezoresistivity effect of a conductive foam made of a flexible polyurethane matrix filled with activated carbon for integrated structural health monitoring (SHM) and low-energy impact detection. To do so, polyurethane foam filled with activated carbon, namely PUF-AC, is tested under quasi-static compressions and under a dynamic mechanical analyzer (DMA) with in situ measurements of its electrical resistance. A new relation is proposed for describing the evolution of the resistivity versus strain rate showing that a link exists between electrical sensitivity and viscoelasticity. In addition, a first demonstrative experiment of feasibility of an SHM application using piezoresistive foam embedded in a composite sandwich structure is realized by a low-energy impact (2 J) test.

A Novel Approach to Water Softening Based on Graphene Oxide-Activated Open Cell Foams

This work focuses on exploring a new configuration for the reduction of water hardness based on the surface modification of polyurethane (PU) open cell foams by the deposition of thin graphene oxide (GO) washcoat layers. GO was deposited by the dip–squeeze coating procedure and consolidated by thermal treatment. The final washcoat load was controlled by performing consecutive depositions, after three of which, a GO inventory up to 27 wt% was obtained onto PU foams of 60 pores per inch (PPI). The GO-coated PU foams were assembled into a filter, and the performance of the system was tested by continuously feeding water with hardness in the 190–270 mgCa2+,eq·L−1 range. Remarkable results were demonstrated in terms of total adsorbing capacity, which was evaluated by measuring the outlet total hardness by titration and exhibited values up to 63 mgCa2+,eq·gGO−1 at a specific filtered water volume of 650 mLH2O·gGO−1, outperforming the actual state-of-the-art adsorbing capacity of similar GO-based materials.

Nanosheet-Stabilized Emulsions: Near-Minimum Loading and Surface Energy Design of Conductive Networks

Here, we develop a framework for assembly, understanding, and application of functional emulsions stabilized by few-layer pristine two-dimensional (2D) nanosheets. Liquid-exfoliated graphene and MoS₂ are demonstrated to stabilize emulsions at ultralow nanosheet volume fractions, approaching the minimum loading achievable with 2D materials. These nanosheet-stabilized emulsions allow controlled droplet deposition free from the coffee ring effect to facilitate single-droplet devices from minute quantities of material or assembly into large-area films with high network conductivity. To broaden the range of compositions and subsequent applications, an understanding of emulsion stability and orientation in terms of surface energy of the three phases is developed. Importantly, this model facilitates determination of the surface energies of the nanosheets themselves and identifies strategies based on surface tension and pH to allow design of emulsion structures. Finally, this approach is used to prepare conductive silicone emulsion composites with a record-low loading level and excellent electromechanical sensitivity. The versatility of these nanosheet-stabilized emulsions illustrates their potential for low-loading composites, thin-film formation and surface energy determination, and the design of functional structures for a range of segregated network applications.

Theoretical Evaluation of Impact Characteristics of Wavy Graphene Sheets with Disclinations Formed by Origami and Kirigami

Evaluation of impact characteristics of carbon nanomaterials is very important and helpful for their application in nanoelectromechanical systems (NEMS). Furthermore, disclination lattice defects can generate out-of-plane deformation to control the mechanical behavior of carbon nanomaterials. In this study, we design novel stable wavy graphene sheets (GSs) using a technique based on origami and kirigami to control the exchange of carbon atoms and generate appropriate disclinations. The impact characteristics of these GSs are evaluated using molecular dynamics (MD) simulation, and the accuracy of the simulation results is verified via a theoretical analysis based on continuum mechanics. In the impact tests, the C₆₀ fullerene is employed as an impactor, and the effects of the different shapes of wavy GSs with different disclinations, different impact sites on the curved surface, and different impact velocities are examined to investigate the impact characteristics of the wavy GSs. We find that the newly designed wavy GSs increasingly resist the kinetic energy (KE) of the impactor as the disclination density is increased, and the estimated KE propagation patterns are significantly different from those of the ideal GS. Based on their enhanced performance in the impact tests, the wavy GSs possess excellent impact behavior, which should facilitate their potential application as high-impact-resistant components in advanced NEMS.

Highly Sensitive Composite Foam Bodily Sensors Based on the g-Putty Ink Soaking Procedure

Electrically conductive composite materials are highlighted as a potential tech path toward future flexible devices for wearable health technologies. To be commercially viable, these materials must not only be mechanically soft, highly sensitive to deformation, and report a sustainable signal but also utilize manufacturing methods that facilitate large-scale production. An ideal candidate for these envisioned technologies is the viscous, electromechanically sensitive composite material g-putty. Inks based on g-putty here are shown to transform a commercial polymer foam into a sensitive strain sensing material through a simple, scalable soaking procedure. Foam composites reported here have sensitives as high as ∼20 in terms of compressive strain and ∼0.4 kPa^-1 with respect to applied compressive stress; both values being comparable to the parent g-putty material. Through g-putty's self-adhering nature, the foams used acted as an elastic scaffolding that aided in overcoming many of the hysteresis effects associated with g-putty without the need for further encapsulation methods. From this, these composite foams were demonstrated to have a sustainable signal that allowed for effective impact and vital sign sensing.

Recent Studies on Dispersion of Graphene-Polymer Composites

Graphene is an excellent 2D material that has extraordinary properties such as high surface area, electron mobility, conductivity, and high light transmission. Polymer composites are used in many applications in place of polymers. In recent years, the development of stable graphene dispersions with high graphene concentrations has attracted great attention due to their applications in energy, bio-fields, and so forth. Thus, this review essentially discusses the preparation of stable graphene-polymer composites/dispersions. Discussion on existing methods of preparing graphene is included with their merits and demerits. Among existing methods, mechanical exfoliation is widely used for the preparation of stable graphene dispersion, the theoretical background of this method is discussed briefly. Solvents, surfactants, and polymers that are used for dispersing graphene and the factors to be considered while preparing stable graphene dispersions are discussed in detail. Further, the direct applications of stable graphene dispersions are discussed briefly. Finally, a summary and prospects for the development of stable graphene dispersions are proposed.

3D printed graphene/polyurethane wearable pressure sensor for motion fitness monitoring

The structural design of three-dimensional (3D) flexible wearable sensors using conductive polymer composites is a hot spot in current research. In this paper, honeycomb-shaped flexible resistive pressure sensors with three different support structures were manufactured by using thermoplastic polyurethane and graphene nanoplatelets composites based on fused deposition 3D printing technology. Based on the various 3D conductive network of the sensors, the flexible sensor exhibit excellent piezoresistive performance, such as adjustable gauge factor (GF) (13.70-54.58), exceptional durability and stability. A combination of representative volume element and finite element simulations was used to simulate the stress distribution of sensors with different structures to predict the structure's effect on the sensor GF. In addition, the sensor can be attached to human body to monitor the body's swallowing and walking behaviors. The sensor has prospective process applications for intelligent wearable devices.

Influence of Anionic Surfactants on the Fundamental Properties of Polymer/Reduced Graphene Oxide Nanocomposite Films

Surfactants are frequently employed in the fabrication of polymer/graphene-based nanocomposites via emulsion techniques. However, the impact of surfactants on the electrical and mechanical properties of such nanocomposite films remains to be explored. We have systematically studied the impact of two anionic surfactants [sodium dodecyl sulfate (SDS) and sodium dodecyl benzene sulfonate (SDBS)] on intrinsic properties of the nanocomposite films comprising reduced graphene oxide in a matrix of poly(styrene-stat-n-butyl acrylate). Using these ambient temperature film-forming systems, we fabricated films with different concentrations of the surfactants (1-7 wt %, relative to the organic phase). Significant differences in film properties were observed both as a function of amount and type of surfactant. Thermally reduced films exhibited concentration-dependent increases in surface roughness, electrical conductivity, and mechanical properties with increasing SDS content. When compared with SDBS, SDS films exhibited an order of magnitude higher electrical conductivity values at every concentration (highest value of ∼4.4 S m^-1 for 7 wt % SDS) and superior mechanical properties at higher surfactant concentrations. The present results illustrate how the simple inclusion of a benzene ring in the SDS structure (as in SDBS) can cause a significant change in the electrical and mechanical properties of the nanocomposite. Overall, the present results demonstrate how nanocomposite properties can be judiciously manipulated by altering the concentration and/or type of surfactant.

3D Graphene Materials: From Understanding to Design and Synthesis Control

Carbon materials, with their diverse allotropes, have played significant roles in our daily life and the development of material science. Following 0D C₆₀ and 1D carbon nanotube, 2D graphene materials, with their distinctively fascinating properties, have been receiving tremendous attention since 2004. To fulfill the efficient utilization of 2D graphene sheets in applications such as energy storage and conversion, electrochemical catalysis, and environmental remediation, 3D structures constructed by graphene sheets have been attempted over the past decade, giving birth to a new generation of graphene materials called 3D graphene materials. This review starts with the definition, classifications, brief history, and basic synthesis chemistries of 3D graphene materials. Then a critical discussion on the design considerations of 3D graphene materials for diverse applications is provided. Subsequently, after emphasizing the importance of normalized property characterization for the 3D structures, approaches for 3D graphene material synthesis from three major types of carbon sources (GO, hydrocarbons and inorganic carbon compounds) based on GO chemistry, hydrocarbon chemistry, and new alkali-metal chemistry, respectively, are comprehensively reviewed with a focus on their synthesis mechanisms, controllable aspects, and scalability. At last, current challenges and future perspectives for the development of 3D graphene materials are addressed.

Stumbling through the Research Wilderness, Standard Methods To Shine Light on Electrically Conductive Nanocomposites for Future Healthcare Monitoring

Electrically conductive nanocomposites are an exciting ever-expanding area of research that has yielded many versatile technologies for wearable health devices. Acting as strain-sensing materials, real-time medical diagnostic tools based on these materials may very well lead to a golden age of healthcare. Currently, the goal in research is to create a material that simultaneously has both a large gauge factor (G) and sensing range. However, a weakness in the area of electromechanical research is the lack of standardization in the reporting of the figure of merit (i.e., G) and the need for other intrinsic metrics to give researchers a more complete view of the research landscape of resistive-type sensors. A paradigm shift in the way in which data are reported is required, to push research in the right direction and to facilitate achieving research goals. Here, we report a standardized method for reporting strain-sensing performance and the introduction of the working factor (W) and the Young's modulus (Y) of a material as figures of merit for sensing materials. Using this standard method, we can define the benchmarks for an optimum sensing material (G > 7, W > 1, Y < 300 kPa) using limits set by standard commercial materials and the human body. Using extrapolated data from 200 publications normalized to this standard method, we can review what composite types meet these benchmark limits, what governs composite performances, the literary trends in composites, and the future prospects of research.

A graphene-based smart thermal conductive system regulated by a reversible pressure-induced mechanism

Thermal dissipation and thermal insulation are important for maintaining the normal operation of devices, extending the service life of instruments, ensuring efficient energy utilization, and improving temperature-related human comfort. Yet it is difficult to achieve both the functions of thermal dissipation and thermal insulation in a single material with a specific thermal conductivity under specific conditions. In this work, based on the huge difference in thermal conductivity between air and reduced graphene oxide (rGO), a pressure-induced mechanism is used to regulate the amount of air inside an rGO foam, so that a periodic reversible change of thermal conductivity can be realized, achieving the dual functions of thermal dissipation and thermal insulation to meet the requirements of different application scenarios. Further fitting calculations suggest that the thermal conductivity of rGO foam is positively and negatively associated with the applied pressure and temperature, respectively, and it can be calculated for given pressure and temperature conditions. The pressure-induced reversible regulation of thermal conductivity in rGO foam provides a new design construct for smart thermal-management devices, and a new direction of application for 2D materials.

A reduced graphene oxide-borate compound-loaded melamine sponge/silicone rubber composite with ultra-high dielectric constant

Herein, at first, graphene oxide (GO) was prepared by a modified Hummers' method, compounded with borates and then loaded onto a melamine sponge (MS) skeleton by an impregnation-reduction method to obtain a reduced graphene oxide (rGO)-borate compound (rGB)-loaded MS. Then, MS/rGB/silicone rubber (SR) composites were prepared by a vacuum infusion process. Moreover, the microstructures, electrical conductivity, and dielectric properties of the composites were investigated. The results showed that rGO presented a sheet-like structure, compounding with borates produced during the reduction of GO by sodium borohydride. rGB was co-loaded onto the MS skeleton, and a three-dimensional percolation network was successfully constructed in the MS/rGB/SR composite. In addition, there was an efficient synergistic effect between rGO and borates, which significantly improved the dielectric constant of the composites. At the rGO volume fraction of 1.89 vol%, the composite had the volume resistivity of 6.57 × 104 Ω cm, the ultra-high dielectric constant of 2.71 × 104 with the dielectric loss of 1.36 at 1 kHz, and the relatively low percolation threshold of 0.815 vol%. Furthermore, the composite exhibited high compression sensitivity at low compressive strains.

A confinement strategy to prepare N-doped reduced graphene oxide foams with desired monolithic structures for supercapacitors

It is a challenge to achieve pure graphene foams with a desired monolithic structure in order to take advantage of the excellent properties of graphene-based macroscopic assemblies. Here, we introduced a confinement fabrication strategy to prepare nitrogen doped reduced graphene oxide foams (NrGFs) through a one-step hydrothermal process. The melamine foam (MF) skeleton was removed during the hydrothermal reaction, and the NrGF retained its desired monolithic structure by the confinement of solution ionic strength. Due to the "roof-tile-like" microscopic morphology with high N-doping (9.88 at%), the free-standing graphene foam electrode exhibited excellent capacitive performance. The resulting NrGF-based symmetric supercapacitor displayed a remarkably enhanced specific capacitance of 260 F g-1 at 0.1 A g-1 and 173 F g-1 at 20 A g-1 in an aqueous electrolyte. Moreover, the facility of fabrication makes it a promising material in many contexts for large scale production, such as energy storage, environmental remediation and strain sensors. Furthermore, this synthesis strategy can be expanded to prepare other pure macroporous foams or composites by using different building blocks (such as CNTs and MXene).

Recent Advances in Flexible and Wearable Pressure Sensors Based on Piezoresistive 3D Monolithic Conductive Sponges

High-performance flexible strain and pressure sensors are important components of the systems for human motion detection, human-machine interaction, soft robotics, electronic skin, etc., which are envisioned as the key technologies for applications in future human healthcare monitoring and artificial intelligence. In recent years, highly flexible and wearable strain/pressure sensors have been developed based on various materials/structures and transduction mechanisms. Piezoresistive three-dimensional (3D) monolithic conductive sponge, the resistance of which changes upon external pressure or stimuli, has emerged as a forefront material for flexible and wearable pressure sensor due to its excellent sensor performance, facile fabrication, and simple circuit integration. This review focuses on the rapid development of the piezoresistive pressure sensors based on 3D conductive sponges. Various piezoresistive conductive sponges are categorized into four different types and their material and structural characteristics are summarized. Methods for preparation of the 3D conductive sponges are reviewed, followed by examples of device performance and selected applications. The review concludes with a critical reflection of the current status and challenges. Prospects of the 3D conductive sponge for flexible and wearable pressure sensor are discussed.

Development of a Highly Sensitive, Broad-Range Hierarchically Structured Reduced Graphene Oxide/PolyHIPE Foam for Pressure Sensing

Highly sensitive pressure sensors are usually made from soft materials that allow large deformations to be obtained when very small pressures are applied. Unfortunately, this current paradigm limits the ability to create sensors capable of high sensitivities and broad dynamic ranges as these materials are prone to saturation responses when attempting to obtain measurements involving high pressures. In this paper, we detail a piezoresistive pressure sensor that is capable of high sensitivity over a pressure range spanning from 0.6 Pa (a mosquito touching a surface) to 200 kPa (an elephant standing on the surface). The sensor's ability to cover such a broad dynamic range is made possible by the fairly hard foam used in its construction as this material is capable of propagating strain in a highly effective manner due to its hierarchical porous structure. The material was fabricated by using high-internal-phase emulsion (HIPE) as a template to generate a highly porous material consisting of small pores packed between larger ones whose inner walls are lined with reduced graphene oxide. The developed foam exhibits very fast response times (less than 15.4 ms) and excellent cyclic stability (at least 10,000 cycles). Furthermore, it is capable of responding to the entire tactile pressure range, and it can be formatted as pixelated arrays, which makes it highly suitable for integration into wearable electronic devices. Such arrays were built and used to identify and render the shape of objects with different geometries, including a sphere, a triangle, a square, and two nearly identical rods differing only by 0.4 mm in diameter.