Topological Gradients for Metal Film-Based Strain Sensors

Stretchable and adhesive bilayers for electrical interfacing

Integrated stretchable devices, containing soft modules, rigid modules, and encapsulation modules, are of potential use in implantable bioelectronics and wearable devices. However, such systems often suffer from electrical deterioration due to debonding failure at the connection between rigid and soft modules induced by severe stress concentration, limiting their practical implementation. Here, we report a highly conductive and adhesive bilayer interface that can reliably connect soft-soft modules and soft-rigid modules together by simply pressing without conductive pastes. This interface configuration features a nanoscale styrene-ethylene-butylene-styrene (SEBS) elastomer layer and a SEBS-liquid metal (LM) composite layer. The top SEBS layer enables a strong adhesion with different modules. The connections between soft-soft and soft-rigid modules can be stretched to high strains of 400% and 250%, respectively. Coupling electron tunneling through an ultrathin SEBS layer with LM particle networks in a SEBS-LM composite layer renders continuous pathways for electrical conductivity. Such a bilayer interface exhibits a strain-insensitive high conductivity (3.7 × 105 S m-1) over a wide strain range from 0 to 680%, which can be facilely fabricated in a self-organized manner by sedimentation of LM particles. We present a proof-of-concept demonstration of this bilayer interface as an electrode, interconnect, and self-solder for monitoring physiological signals.

Highly Robust and Self-Adhesive Soft Strain Gauge via Interface Design Engineering

Highly robust soft strain gauges are rapidly emerging as a promising candidate in the fields of vital signs and machine conditions monitoring. However, it is still a key challenge to achieve high-performance strain sensing in these sensors with mechanical/electrical robustness for long-term usage. The multilayer structural design of sensors enhances sensing performance while the interfacial connection of heterogeneous materials between different layers is weak. Herein, inspired by the efficient perception mechanism of scorpion slit sensilla with tough interface interconnections, the synergy of ultra-high electrical performance and mechanical robustness is successfully achieved via interface design engineering. The developed multilayer soft strain gauge (MSSG) exhibits a strain sensitivity beyond 105, a lower detection limit of 8.3 µm, a frequency resolution within 0.1 Hz, and cyclic stability over 63 000 strain cycles. Also, the tough interface improves the level of heterogeneous integration in the MSSG which allows to endure different stresses. Furthermore, an MSSG-based wireless strain monitoring system is developed that enables applications on different complex dynamic surfaces, including accurate identification of human throat activity and monitoring of rolling bearing conditions.

Interfacial Wrinkling Structures Based on a Double Cross-Linking Strategy Enable a Dual-Mode Optical Information Encryption

Surface wrinkling structures based on a bilayer system are widely employed in storing and encrypting specific optical information. However, constructing a stable wrinkling structure with high-level security remains an extensive challenge due to the delamination issue between the skin layer and the substrate. Herein, a double cross-linking strategy is introduced between a hydrogel layer doped with fluorescent molecules and polydimethylsiloxane to establish a stable interfacial wrinkling structure with dual-mode functionality, in which the light reflection of the wrinkles and fluorescence intensity of fluorescent molecules can be simultaneously regulated by the modulus ratio between the two layers. The spontaneous wrinkling structures with a physically unclonable function can enhance the photoluminescence emission intensity of the wrinkling area under ultraviolet radiation. Meanwhile, the skin layer constructed of acrylamide and acrylic acid copolymer protects the interfacial wrinkling patterns from the loss of a detailed structure for authentication due to external damage. The stable interfacial wrinkling structures with fluorescence can find potential applications in the fields of information storage and encryption.

Batch Fabrication of Flexible Strain Sensors with High Linearity and Low Hysteresis for Health Monitoring and Motion Detection

In recent years, flexible strain sensors have gradually come into our lives due to their superiority in the field of biomonitoring. However, these sensors still suffer from poor durability, high hysteresis, and difficulty in calibration, resulting in great hindrance of practical application. Herein, starting with interfacial interaction regulation and structure-induced cracking, flexible strain sensors with high performance are successfully fabricated. In this strategy, dopamine treatment is used to enhance the bonding between flexible substrates and carbon nanotubes (CNT). The combination within the conductive networks is then controlled by substituting the CNT type. Braid-like fibers are employed to achieve controllable expansion of the conductive layer cracks. Finally, we obtain strain sensors that possess high linearity (R2 = 0.997) with low hysteresis (5%), high sensitivity (GF = 60) and wide sensing range (0-50%), short response time (62 ms), outstanding stability, and repeatability (>10,000 cycles). Flexible strain sensors with all performances good are rarely reported. Static and dynamic respiration and pulse signal monitoring by the fiber sensor are demonstrated. Moreover, a knee joint monitoring system is constructed for the monitoring of various walking stances, which is of great value to the diagnosis and rehabilitation of many diseases.

A Highly Sensitive Strain Sensor with Wide Linear Sensing Range Prepared on a Hybrid-Structured CNT/Ecoflex Film via Local Regulation of Strain Distribution

With the development of information technology, high-performance wearable strain sensors with high sensitivity and stretchability have played a significant role in motion detection. However, many high-sensitivity and outstanding-stretchability strain sensors possess a limited linear sensing range, which limits the enhancement of the flexible strain sensors' performance. Herein, we develop a hybrid-structured carbon nanotube (CNT)/Ecoflex strain sensor with laser-engraved grooves along with punched circular holes in a composite CNT/Ecoflex film by vacuum filtration and permeation. By optimizing the distribution of grooves and circular holes, the strain in the sensing layer can be locally regulated, which alters the morphology of cracks under strain and allows the hybrid-structured CNT/Ecoflex strain sensor to simultaneously exhibit high sensitivity (GF = 43.8) as well as a wide linear sensing range (200%). On the basis of excellent performance, the hybrid-structured CNT/Ecoflex strain sensor is capable of detecting movements in various parts of the human body, including movements of larynx and joint bending.

Materials-Driven Soft Wearable Bioelectronics for Connected Healthcare

In the era of Internet-of-things, many things can stay connected; however, biological systems, including those necessary for human health, remain unable to stay connected to the global Internet due to the lack of soft conformal biosensors. The fundamental challenge lies in the fact that electronics and biology are distinct and incompatible, as they are based on different materials via different functioning principles. In particular, the human body is soft and curvilinear, yet electronics are typically rigid and planar. Recent advances in materials and materials design have generated tremendous opportunities to design soft wearable bioelectronics, which may bridge the gap, enabling the ultimate dream of connected healthcare for anyone, anytime, and anywhere. We begin with a review of the historical development of healthcare, indicating the significant trend of connected healthcare. This is followed by the focal point of discussion about new materials and materials design, particularly low-dimensional nanomaterials. We summarize material types and their attributes for designing soft bioelectronic sensors; we also cover their synthesis and fabrication methods, including top-down, bottom-up, and their combined approaches. Next, we discuss the wearable energy challenges and progress made to date. In addition to front-end wearable devices, we also describe back-end machine learning algorithms, artificial intelligence, telecommunication, and software. Afterward, we describe the integration of soft wearable bioelectronic systems which have been applied in various testbeds in real-world settings, including laboratories that are preclinical and clinical environments. Finally, we narrate the remaining challenges and opportunities in conjunction with our perspectives.

Outstanding Synergy of Sensitivity and Linear Range Enabled by Multigradient Architectures

Flexible pressure sensors are devices that mimic the sensory capabilities of natural human skin and enable robots to perceive external stimuli. One of the main challenges is maintaining high sensitivity over a broad linear pressure range due to poor structural compressibility. Here, we report a flexible pressure sensor with an ultrahigh sensitivity of 153.3 kPa-1 and linear response over an unprecedentedly broad pressure range from 0.0005 to 1300 kPa based on interdigital-shaped, multigradient architectures, featuring modulus, conductivity, and microstructure gradients. Such multigradient architectures and interdigital-shaped configurations enable effective stress transfer and conductivity regulation, evading the pressure sensitivity-linear range trade-off dilemma. Together with high pressure resolution, high frequency response, and good reproducibility over the ultrabroad linear range, proof-of-concept applications such as acoustic wave detection, high-resolution pressure measurement, and healthcare monitoring in diverse scenarios are demonstrated.

Highly stable and strain-insensitive metal film conductors via manipulating strain distribution

Metal film-based stretchable conductors are essential elements of flexible electronics for wearable, biomedical, and robotic applications, which require strain-insensitive high conductivity over a wide strain range and excellent cyclic stability. However, they suffer from serious electrical failure under monotonic and cyclic tensile loading at a small strain due to the uncontrolled film cracking behavior. Here, we propose a novel in-plane crack control strategy of engineering hierarchical microstructures to achieve outstanding electromechanical performance via harnessing the strain distribution in metal films. The wrinkles delay the crack initiation at undercuts which should be the most vulnerable sites during the stretching process. The surface protrusions/grooves/undercuts inhibit the crack propagation because of the effective strain redistribution. In addition, hierarchical microstructures significantly improve cyclic stability due to the strong interfacial adhesion and stable crack patterns. The metal film-based conductors exhibit ultrahigh strain-insensitive conductivity (1.7 × 107 S m-1), negligible resistance change (ΔR/R0 = 0.007) over an ultra-wide strain range (>200%), and excellent cyclic strain durability (>15 000 cycles at 100% strain). A range of metal films was explored to establish the universality of this strategy, including ductile copper and silver, as well as brittle molybdenum and high entropy alloy. We demonstrate the strain-insensitive electrical functionality of a metal film-based conductor in a flexible light-emitting diode circuit.

High-performance flexible strain sensors based on silver film wrinkles modulated by liquid PDMS substrates

Flexible strain sensors based on controllable surface microstructures in film-substrate systems can be extensively applied in high-tech fields such as human-machine interfaces, electronic skins, and soft robots. However, the rigid functional films are susceptible to structural destruction and interfacial failure under large strains or high loading speeds, limiting the stability and durability of the sensors. Here we report on a facile technique to prepare high-performance flexible strain sensors based on controllable wrinkles by depositing silver films on liquid polydimethylsiloxane (PDMS) substrates. The silver atoms can penetrate into the surface of liquid PDMS to form an interlocking layer during deposition, enhancing the interfacial adhesion greatly. After deposition, the liquid PDMS is spontaneously solidified to stabilize the film microstructures. The surface patterns are well modulated by changing film thickness, prepolymer-to-crosslinker ratio of liquid PDMS, and strain value. The flexible strain sensors based on the silver film/liquid PDMS system show high sensitivity (above 4000), wide sensing range (∼80%), quick response speed (∼80 ms), and good stability (above 6000 cycles), and have a broad application prospect in the fields of health monitoring and motion tracking.

A Review of Structure Engineering of Strain-Tolerant Architectures for Stretchable Electronics

Stretchable electronics possess significant advantages over their conventional rigid counterparts and boost game-changing applications such as bioelectronics, flexible displays, wearable health monitors, etc. It is, nevertheless, a formidable task to impart stretchability to brittle electronic materials such as silicon. This review provides a concise but critical discussion of the prevailing structural engineering strategies for achieving strain-tolerant electronic devices. Not only the more commonly discussed lateral designs of structures such as island-bridge, wavy structures, fractals, and kirigami, but also the less discussed vertical architectures such as strain isolation and elastoplastic principle are reviewed. Future opportunities are envisaged at the end of the paper.

High Sensitivity, Wide Linear-Range Strain Sensor Based on MXene/AgNW Composite Film with Hierarchical Microcrack

Stretchable strain sensors suffer the trade-off between sensitivity and linear sensing range. Developing sensors with both high sensitivity and wide linear range remains a formidable challenge. Different from conventional methods that rely on the structure design of sensing nanomaterial or substrate, here a heterogeneous-surface strategy for silver nanowires (AgNWs) and MXene is proposed to construct a hierarchical microcrack (HMC) strain sensor. The heterogeneous surface with distinct differences in cracks and adhesion strengths divides the sensor into two regions. One region contributes to high sensitivity through penetrating microcracks of the AgNW/MXene composite film during stretching. The other region maintains conductive percolation pathways to provide a wide linear sensing range through network microcracks. As a result, the HMC sensor exhibits ultrahigh sensitivity (gauge factor ≈ 244), broad linear range (ɛ = 60%, R2 ≈ 99.25%), and fast response time (<30 ms). These merits are confirmed in the detection of large and subtle human motions and digital joint movement for Morse coding. The manipulation of cracks on the heterogeneous surface provides a new paradigm for designing high-performance stretchable strain sensors.

Wrinkled Thermo-Electric Meander-Shaped Element on a Thin Freestanding PDMS Membrane

Natural wrinkling of metal films on silicone substrates can appear by means of the metal sputtering process and can be described by the continuous elastic theory and non-linear wrinkling model. Here, we report the fabrication technology and behavior of thin freestanding Polydimethylsiloxane (PDMS) membranes equipped with thermo-electric meander-shaped elements. The Cr/Au wires were obtained on the silicone substrate by magnetron sputtering. We observe wrinkle formation and suppose furrows appear once PDMS returns to its initial state after the thermo-mechanical expansion during sputtering. Although the substrate thickness is usually a negligible parameter in the theory of wrinkle formation, we found that the self-assembled wrinkling architecture of the PDMS/Cr/Au varies due to the membrane thickness of 20 µm and 40 µm PDMS. We also demonstrate that the wrinkling of the meander wire affects its length, and it causes a 2.7 times higher resistance compared to a calculated value. Therefore, we investigate the influence of the PDMS mixing ratio on the thermo-electric meander-shaped elements. For the stiffer PDMS with a mixing ratio of 10:4, the resistance due to wrinkle amplitude alterations is 25% higher compared to the PDMS of ratio 10:1. Additionally, we observe and describe a thermo-mechanically induced motion behavior of the meander wires on completely freestanding PDMS membrane under applied current. These results can improve the understanding of wrinkle formation, which influences thermo-electric characteristics and may promote the integration of this technology in applications.

Defining the zerogap: cracking along the photolithographically defined Au-Cu-Au lines with sub-nanometer precision

Cracks are formed along the photolithographically pre-determined lines with extremely high yield and repeatability, when Cu clusters are introduced between planarized Au thin films sequentially deposited on a PET substrate. These clusters act as nanometer-sized spacers preventing the formation of contiguous metallic bond between the adjacent Au layers which will render prepatterned-cracking impossible. While the effective gap width is initially zero in the optical sense from microwaves all the way to the visible, outer-bending the PET substrate allows the gap width tuning into the 100 nm range, with the stability and controllability in the ranges of 100 s and Angstrom-scale, respectively. It is anticipated that our wafer-scale prepatterned crack technology with an unprecedented mixture of macroscopic length and Angstrom-scale controllability will open-up many applications in optoelectronics, quantum photonics and photocatalysis.