Dual-Scale Porous Composite for Tactile Sensor with High Sensitivity over an Ultrawide Sensing Range

Ultrawide linear range, high sensitivity, and large-area pressure sensor arrays enabled by pneumatic spraying broccoli-like microstructures

Large-area pressure sensor arrays with a wide linear response range and high sensitivity are beneficial to map the inhomogeneous interface pressure, which is significant in practical applications. Here, we demonstrate a pneumatic spraying method to prepare large-area microstructure films (PSMF) for high performance pressure sensor arrays. The sprayed surface morphology is designable by controlling the spraying parameters. It is worth noting that the constructed "broccoli" like morphology with a swollen top and shrunken bottom inspired a new mechanism to enlarge the linear response range by decreasing the series resistance with pressure increasing. At the same time, the pneumatic sprayed "broccoli" has a rough surface due to droplet stacking, which reduces the initial current effectively. Hence, the sensor achieves a 10 000 kPa ultrawide linear response range with a high sensitivity (98.71 kPa-1), and low detection (5 Pa). The prepared sensor has a small static response error (4.4%) and 5000 cycle full-range dynamic response durability. Finally, the constructed sensor arrays can distinguish the pressure distribution in different ranges clearly, which indicates a great potential in health care, motion detection, and the tire industry.

Self-Assembly of Multiwalled Carbon Nanotubes on a Silicone Rubber Foam Skeleton for Durable Piezoresistive Sensors

Conductive nanomaterial/flexible polymer composite foams are of great interest in the field of flexible and wearable piezoresistive pressure sensors. However, the existing composite foam sensors are faced with stability issues from conductive nanomaterials, which tends to decrease their long-term durability. Herein, we developed a solvent evaporation-induced self-assembly strategy, which could significantly improve the stability of multiwalled carbon nanotubes (MWCNTs) on a silicone rubber foam skeleton. The process for self-assembly of MWCNTs was straightforward. Aqueous MWCNT dispersion droplets were first hierarchically enclosed in silicone rubber via water-in-oil (W/O) Pickering high internal phase emulsions (HIPEs). Then, the high pressure generated by fast evaporation of the solvent from the droplets could break the thinnest pore walls to form interconnected pores. As a result, very dense and firm MWCNT layers were self-assembled on the pore wall surface. Due to the excellent stability of MWCNTs and tetramodal interconnected porosity, our MWCNTs/silicone rubber composite foam showed the following "super" properties: low density of 0.26 g/mL, high porosity of 76%, and excellent mechanical strength (the maximum stress loss of 8.3% at 80% strain after 100 compression cycles). In addition, excellent piezoresistive performance, including superior discernibility for different amplitudes of compressive strain (up to 80%), rapid response time (150 ms), and high sensitivity (gauge factor of 1.44), was demonstrated for such foams, together with prominent durability (39,000 compression cycles at 60% strain in air) and excellent stability of resistance response in water and organic solvents (5000 compression cycles at 30% strain in water and ethanol). Regarding its application, a wearable piezoresistive sensor, which was assembled from the as-prepared conductive silicone rubber composite foam, could capture various movements from tiptoeing and finger bending to small deformations resulting from human pulse.

Ultra-Wide Range, High Sensitivity Piezoresistive Sensor Based on Triple Periodic Minimum Surface Construction

Flexible piezoresistive sensors with biological structures are widely exploited for high sensitivity and detection. However, the conventional bionic structure pressure sensors usually suffer from irreconcilable conflicts between high sensitivity and wide detection response range. Herein, a triple periodic minimum surface (TPMS) structure sensor is proposed based on parametric structural design and 3D printing techniques. Upon tailoring of the dedicated structural parameters, the resulting sensors exhibit superior compression durability, high sensitivity, and ultra-high detection range, that enabling it meets the needs of various scenes. As a model system, TPMS structure sensor with 40.5% porosity exhibits an ultra-high sensitivity (132 kPa-1 in 0-5.7 MPa), wide detection strain range (0-31.2%), high repeatability and durability (1000 cycles in 4.41 MPa, 10000 s in 1.32 MPa), and low detection limit (1% in 80 kPa). The stress/strain distributions have been identified using finite element analysis. Toward practical applications, the TPMS structural sensors can be applied to detect human activity and health monitoring (i.e., voice recognition, finger pressure, sitting, standing, walking, and falling down behaviors). The synergistic effects of MWCNTs and MXene conductive network also ensure the composite further being utilized for electromagnetic interference shielding applications.

Wearable Pressure Sensor Using Porous Natural Polymer Hydrogel Elastomers with High Sensitivity over a Wide Sensing Range

Wearable pressure sensors capable of quantifying full-range human dynamic motionare are pivotal in wearable electronics and human activity monitoring. Since wearable pressure sensors directly or indirectly contact skin, selecting flexible soft and skin-friendly materials is important. Wearable pressure sensors with natural polymer-based hydrogels are extensively explored to enable safe contact with skin. Despite recent advances, most natural polymer-based hydrogel sensors suffer from low sensitivity at high-pressure ranges. Here, by using commercially available rosin particles as sacrificial templates, a cost-effective wide-range porous locust bean gum-based hydrogel pressure sensor is constructed. Due to the three-dimensional macroporous structure of the hydrogel, the constructed sensor exhibits high sensitivities (12.7, 5.0, and 3.2 kPa^-1 under 0.1-20, 20-50, and 50-100 kPa) under a wide range of pressure. The sensor also offers a fast response time (263 ms) and good durability over 500 loading/unloading cycles. In addition, the sensor is successfully applied for monitoring human dynamic motion. This work provides a low-cost and easy fabrication strategy for fabricating high-performance natural polymer-based hydrogel piezoresistive sensors with a wide response range and high sensitivity.