Development of a Waterproof Crack-Based Stretchable Strain Sensor Based on PDMS Shielding

Stretchable Electronics with Strain-Resistive Performance

Stretchable electronics have attracted tremendous attention amongst academic and industrial communities due to their prospective applications in personal healthcare, human-activity monitoring, artificial skins, wearable displays, human-machine interfaces, etc. Other than mechanical robustness, stable performances under complex strains in these devices that are not for strain sensing are equally important for practical applications. Here, a comprehensive summarization of recent advances in stretchable electronics with strain-resistive performance is presented. First, detailed overviews of intrinsically strain-resistive stretchable materials, including conductors, semiconductors, and insulators, are given. Then, systematic representations of advanced structures, including helical, serpentine, meshy, wrinkled, and kirigami-based structures, for strain-resistive performance are summarized. Next, stretchable arrays and circuits with strain-resistive performance, that integrate multiple functionalities and enable complex behaviors, are introduced. This review presents a detailed overview of recent progress in stretchable electronics with strain-resistive performances and provides a guideline for the future development of stretchable electronics.

Strain Sensors Made of MXene, CNTs, and TPU/PSF Asymmetric Structure Films with Large Tensile Recovery and Applied in Human Health Monitoring

Designing flexible wearable sensors with a wide sensing range, high sensitivity, and high stability is a vulnerable research direction with a futuristic field to study. In this paper, Ti3C2Tx MXene/carbon nanotube (CNT)/thermoplastic polyurethane (TPU)/polysulfone (PSF) composite films with excellent sensor performance were obtained by self-assembly of conductive fillers in TPU/PSF porous films with an asymmetric structure through vacuum filtration, and the porous films were prepared by the phase inversion method. The composite films consist of the upper part with finger-like "cavities" filled by MXene/CNTs, which reduces the microcracks in the conductive network during the tensile process, and the lower part has smaller apertures of a relatively dense resin cortex assisting the recovery process. The exclusive layer structure of the MXene/CNTs/TPU/PSF film sensor, with a thickness of 46.95 μm, contains 0.0339 mg/cm2 single-walled carbon nanotubes (SWNTs) and 0.348 mg/cm2 MXene only, providing functional range (0-80.7%), high sensitivity (up to 1265.18), and excellent stability and durability (stable sensing under 2300 fatigue tests, viable to the initial resistance), endurably cycled under large strains with serious damage to the conductive network. Finally, the MXene/CNTs/TPU/PSF film sensor is usable for monitoring pulse, swallow, tiptoe, and various joint bends in real time and distributing effective electrical signals. This paper implies that the MXene/CNTs/TPU/PSF film sensor has broad prospects in pragmatic applications.

Multimodal Wearable Ionoskins Enabling Independent Recognition of External Stimuli Without Crosstalk

Wearable ionoskins are one of the representative examples of the many useful applications offered by deformable stimuli-responsive sensory platforms. Herein, ionotronic thermo-mechano-multimodal response sensors are proposed, which can independently detect changes in temperature and mechanical stimuli without crosstalk. For this purpose, mechanically robust, thermo-responsive ion gels composed of poly(styrene-ran-n-butyl methacrylate) (PS-r-PnBMA, copolymer gelator) and 1-butyl-3-methylimidazolium bis(trifluoromethyl sulfonyl)imide ([BMI][TFSI], ionic liquid) are prepared. The optical transmittance change arising from the lower critical solution temperature (LCST) phenomenon between PnBMA and [BMI][TFSI] is exploited to track the external temperature, creating a new concept of the temperature coefficient of transmittance (TCT). The TCT of this system (-11.5% °C-1 ) is observed to be more sensitive to temperature fluctuations than the conventional metric of temperature coefficient of resistance. The tailoring molecular characteristics of gelators selectively improved the mechanical robustness of the gel, providing an additional application opportunity for strain sensors. This functional sensory platform, which is attached to a robot finger, can successfully detect thermal and mechanical environmental changes through variations in the optical (transmittance) and electrical (resistance) properties of the ion gel, respectively, indicating the high practicality of on-skin multimodal wearable sensors.

A nanonewton-scale biomimetic mechanosensor

Biomimetic mechanosensors have profound implications for various areas, including health care, prosthetics, human‒machine interfaces, and robotics. As one of the most important parameters, the sensitivity of mechanosensors is intrinsically determined by the detection resolution to mechanical force. In this manuscript, we expand the force detection resolution of current biomimetic mechanosensors from the micronewton to nanonewton scale. We develop a nanocrack-based electronic whisker-type mechanosensor that has a detection resolution of 72.2 nN. We achieve the perception of subtle mechanical stimuli, such as tiny objects and airflow, and the recognition of surface morphology down to a 30 nm height, which is the finest resolution ever reported in biomimetic mechanosensors. More importantly, we explore the use of this mechanosensor in wearable devices for sensing gravity field orientation with respect to the body, which has not been previously achieved by these types of sensors. We develop a wearable smart system for sensing the body's posture and movements, which can be used for remote monitoring of falls in elderly people. In summary, the proposed device offers great advantages for not only improving sensing ability but also expanding functions and thus can be used in many fields not currently served by mechanosensors.

Research status of polysiloxane-based piezoresistive flexible human electronic sensors

Flexible human body electronic sensor is a multifunctional electronic device with flexibility, extensibility, and responsiveness. Piezoresistive flexible human body electronic sensor has attracted the extensive attention of researchers because of its simple preparation process, high detection sensitivity, wide detection range, and low power consumption. However, the wearability and affinity to the human body of traditional flexible human electronic sensors are poor, while polysiloxane materials can be mixed with other electronic materials and have good affinity toward the human body. Therefore, polysiloxane materials have become the first choice of flexible matrixes. In this study, the research progress and preparation methods of piezoresistive flexible human electronic sensors based on polysiloxane materials in recent years are summarized, the challenges faced in the development of piezoresistive flexible human electronic sensors are analyzed, and the future research directions are prospected.

Design of 3D Controller Using Nanocracking Structure-Based Stretchable Strain Sensor

In this study, we introduce a novel design for a three-dimensional (3D) controller, which incorporates the omni-purpose stretchable strain sensor (OPSS sensor). This sensor exhibits both remarkable sensitivity, with a gauge factor of approximately 30, and an extensive working range, accommodating strain up to 150%, thereby enabling accurate 3D motion sensing. The 3D controller is structured such that its triaxial motion can be discerned independently along the X, Y, and Z axes by quantifying the deformation of the controller through multiple OPSS sensors affixed to its surface. To ensure precise and real-time 3D motion sensing, a machine learning-based data analysis technique was implemented for the effective interpretation of the multiple sensor signals. The outcomes reveal that the resistance-based sensors successfully and accurately track the 3D controller's motion. We believe that this innovative design holds the potential to augment the performance of 3D motion sensing devices across a diverse range of applications, encompassing gaming, virtual reality, and robotics.

Progress in Microtopography Optimization of Polymers-Based Pressure/Strain Sensors

Due to the wide application of wearable electronic devices in daily life, research into flexible electronics has become very attractive. Recently, various polymer-based sensors have emerged with great sensing performance and excellent extensibility. It is well known that different structural designs each confer their own unique, great impacts on the properties of materials. For polymer-based pressure/strain sensors, different structural designs determine different response-sensing mechanisms, thus showing their unique advantages and characteristics. This paper mainly focuses on polymer-based pressure-sensing materials applied in different microstructures and reviews their respective advantages. At the same time, polymer-based pressure sensors with different microstructures, including with respect to their working mechanisms, key parameters, and relevant operating ranges, are discussed in detail. According to the summary of its performance and mechanisms, different morphologies of microstructures can be designed for a sensor according to its performance characteristics and application scenario requirements, and the optimal structure can be adjusted by weighing and comparing sensor performances for the future. Finally, a conclusion and future perspectives are described.

Flexible Sensory Systems: Structural Approaches

Biology is characterized by smooth, elastic, and nonplanar surfaces; as a consequence, soft electronics that enable interfacing with nonplanar surfaces allow applications that could not be achieved with the rigid and integrated circuits that exist today. Here, we review the latest examples of technologies and methods that can replace elasticity through a structural approach; these approaches can modify mechanical properties, thereby improving performance, while maintaining the existing material integrity. Furthermore, an overview of the recent progress in wave/wrinkle, stretchable interconnect, origami/kirigami, crack, nano/micro, and textile structures is provided. Finally, potential applications and expected developments in soft electronics are discussed.

Development and Characteristics of Multipurpose Transparent Polyurethane Film

In industry, recent research developments include flexible films and foldable films. The next step is the development of stretchable films, and studies are being intensively carried out. Research on the development of stretchable and transparent materials is also increasing greatly. Currently, polydimethylsiloxane (PDMS) is the most commonly used film in the industry. However, PDMS surfaces are hydrophobic, so their use is limited to making materials and compounds with hydrophilic properties. In this study, we developed a transparent polyurethane film that can be used for multiple purposes. A transparency comparison between the transparent polyurethane film and the general polyurethane film was used to verify their future application. The conventional polyurethane films showed a transmittance rate of 2.2 percent, but the transparent polyurethane films achieved a high transmittance rate of 85 percent. To determine whether the film can be realized, we produced a conductive paste using resin for the transparent polyurethane film. In addition, a conductive paste was made based on the material used in the transparent polyurethane film to verify the hardness and reliability of the adhesion of electrodes, and we confirmed this with thermogravimetric analysis (TGA). The transparent polyurethane based paste was made with stretchable electrodes through a screen printing method. The manufactured stretchable electrodes were demonstrated by mechanical and adhesion tests. Finally, a permittivity test was conducted to determine the suitability of the film for application to printed electrodes for antennas in the future. The genetic rate of transparent polyurethane films was better than that of conventional polyurethane films. Moreover, the adhesion of the transparent polyurethane film and stretchable electrodes was as good as that of conventional polyurethane film and stretchable electrodes, and observation by optical microscopy confirmed that the printing performance was also excellent. In addition, the conductive paste made based on the transparent polyurethane film material was cured for 1 hour at 120 °C, and TGA analysis confirmed that both the binders and curing agent responded well in the test for curing the developed stretchable electrodes and transparent polyurethane.

Printed Strain Sensors Based on an Intermittent Conductive Pattern Filled with Resistive Ink Droplets

In this study, we demonstrate a strain sensor fabricated as a hybrid structure of a conductive intermittent pattern with embedded single droplets of a functional resistive ink. The main feature of our proposed sensor design is that although the intermittent pattern comprises the majority of the entire sensor area, the strain sensitivity depends almost selectively on the resistive droplets. This opens up the possibility for fast and inexpensive evaluation of sensors manufactured from various functional materials. As the use of resistive ink was limited to single droplets deposition, the required ink amount needed to build a sensor can be considerably reduced. This makes the sensors cost-effective and simple for fabrication. In this study, our proposed sensor design was evaluated when a carbon-based ink was used as the resistive material incorporated into an intermittent structure made of silver. The developed strain sensors were tested during bending deformations demonstrating good strain sensitivity (gauge factor: 7.71) and no hysteresis within the investigated strain range.

Recent progress in controlled nano/micro cracking as an alternative nano-patterning method for functional applications

Generally, cracking occurs for many reasons connected to uncertainties and to the non-uniformity resulting from intrinsic deficiencies in materials or the non-linearity of applied external (thermal, mechanical, etc.) stresses. However, recently, an increased level of effort has gone into analyzing the phenomenon of cracking and also into methods for controlling it. Sophisticated manipulation of cracking has yielded various cutting-edge technologies such as transparent conductors, mechanical sensors, microfluidics, and energy devices. In this paper, we present some of the recent progress that has been made in controlling cracking by giving an overview of the fabrication methods and working mechanisms used for various mediums. In addition, we discuss recent progress in the various applications of methods that use controlled cracking as an alternative to patterning tools.

Flexible Capacitive Curvature Sensor with One-Time Calibration for Amphibious Gait Monitoring

Wearable devices developed with flexible electronics have great potential applications for human health monitoring and motion sensing. Although material softness and structural flexibility provide a deformable human-machine interface to adapt to joint bending or tissue stretching/compression, flexible sensors are inconvenient in practical uses as they usually require calibration every time they are installed. This article presents an approach to design and fabricate a flexible curvature sensor to measure human articular movements for amphibious applications. This flexible sensor employs the capacitive sensing principle, where the dielectric layer and electrodes are made from the polyurethane resin and eutectic gallium-indium (EGaIn) liquid metal; and the fabrication process is implemented with shape deposition molding for batch production. The sensing method for articular rotation angles employs the Euler beam model to make the sensor reusable after one-time calibration by compensating for the unpredicted manual installation error. The illustrative application to ankle sensing in amphibious gaits shows that the root-mean-square error is within 5° for different walking speeds (0.7-1.1 m/s) in treadmill tests and the maximum error is within 3° for underwater sensing with quasi-static measurements. It is expected that the proposed waterproof flexible sensor can push the boundaries of wearable robotics, human locomotion, as well as their related applications.

Highly durable crack sensor integrated with silicone rubber cantilever for measuring cardiac contractility

To date, numerous biosensing platforms have been developed for assessing drug-induced cardiac toxicity by measuring the change in contractile force of cardiomyocytes. However, these low sensitivity, low-throughput, and time-consuming processes are severely limited in their real-time applications. Here, we propose a cantilever device integrated with a polydimethylsiloxane (PDMS)-encapsulated crack sensor to measure cardiac contractility. The crack sensor is chemically bonded to a PDMS thin layer that allows it to be operated very stably in culture media. The reliability of the proposed crack sensor has been improved dramatically compared to no encapsulation layer. The highly sensitive crack sensor continuously measures the cardiac contractility without changing its gauge factor for up to 26 days (>5 million heartbeats), while changes in contractile force induced by drugs are monitored using the crack sensor-integrated cantilever. Finally, experimental results are compared with those obtained via conventional optical methods to verify the feasibility of building a contraction-based drug-toxicity testing system.

Measuring cardiac contractility is challenging. Here, the authors encapsulated a crack-based sensor with polydimethylsiloxane, thereby endowing the sensor with the stability to measure cardiac contractility for up to 26 days as well as monitoring drug-induced cardiac toxicity in cell culture.

Design and applications of stretchable and self-healable conductors for soft electronics

Soft and conformable electronics are emerging rapidly and is envisioned as the future of next-generation electronic devices where devices can be readily deployed in various environments, such as on-body, on-skin or as a biomedical implant. Modern day electronics require electrical conductors as the fundamental building block for stretchable electronic devices and systems. In this review, we will study the various strategies and methods of designing and fabricating materials which are conductive, stretchable and self-healable, and explore relevant applications such as flexible and stretchable sensors, electrodes and energy harvesters.

A Highly Sensitive Capacitive-type Strain Sensor Using Wrinkled Ultrathin Gold Films

Soft strain sensors are needed for a variety of applications including human motion and health monitoring, soft robotics, and human/machine interactions. Capacitive-type strain sensors are excellent candidates for practical applications due to their great linearity and low hysteresis; however, a big limitation of this sensor is its inherent property of low sensitivity when it comes to detecting various levels of applied strain. This limitation is due to the structural properties of the parallel plate capacitor structure during applied stretching operations. According to this model, at best the maximum gauge factor (sensitivity) that can be achieved is 1. Here, we report the highest gauge factor ever achieved in capacitive-type strain sensors utilizing an ultrathin wrinkled gold film electrode. Our strain sensor achieved a gauge factor slightly above 3 and exhibited high linearity with negligible hysteresis over a maximum applied strain of 140%. We further demonstrated this highly sensitive strain sensor in a wearable application. This work opens up the possibility of engineering even higher sensitivity in capacitive-type strain sensors for practical and reliable wearable applications.

One-Step Laser Encapsulation of Nano-Cracking Strain Sensors

Development of flexible strain sensors that can be attached directly onto the skin, such as skin-mountable or wearable electronic devices, has recently attracted attention. However, such flexible sensors are generally exposed to various harsh environments, such as sweat, humidity, or dust, which cause noise and shorten the sensor lifetimes. This study reports the development of a nano-crack-based flexible sensor with mechanically, thermally, and chemically stable electrical characteristics in external environments using a novel one-step laser encapsulation (OLE) method optimized for thin films. The OLE process allows simultaneous patterning, cutting, and encapsulating of a device using laser cutting and thermoplastic polymers. The processes are simplified for economical and rapid production (one sensor in 8 s). Unlike other encapsulation methods, OLE does not degrade the performance of the sensor because the sensing layers remain unaffected. Sensors protected with OLE exhibit mechanical, thermal, and chemical stability under water-, heat-, dust-, and detergent-exposed conditions. Finally, a waterproof, flexible strain sensor is developed to detect motions around the eye, where oil and sweat are generated. OLE-based sensors can be used in several applications that are exposed to a large amount of foreign matter, such as humid or sweaty environments.

Multifunctional Nanocracks in Silicon Nanomembranes by Notch-Assisted Transfer Printing

Manipulating nanocracks to produce various nanodevices has attracted increasing interest. Here, based on the mature transfer printing technique, a novel notch-assisted transfer printing technique was engaged to produce nanocracks by simply introducing notch structures into the transferred nanomembranes. Both experiments and finite element simulations were used to elucidate the probability of nanocrack formation during the transfer process, and the results demonstrated that the geometry of nanomembranes played a key role in concentrating stress and producing nanocracks. We further demonstrated that the obtained nanocrack can be used as a surface-enhanced Raman scattering substrate because of the significant enhancement of electric fields. In addition, the capillary condensation of water molecules in the nanocrack led to an obvious change of resistance, thus providing an opportunity for the crack-based structure to be used as an ultrasensitive humidity sensor. The current approach can be applied to producing nanocracks from multiple materials and will have important applications in the field of nanodevices.