Near-Zero Hysteresis Ionic Conductive Elastomers with Long-Term Stability for Sensing Applications

Synergistic Structural Construction of Strain Sensors with Low Baseline Drift and High Sensitivity for Continuous Dynamic Monitoring

Strain sensors based on conductive elastomers face challenges like baseline drift and noise due to inherent viscoelasticity and weak electrode interfaces under dynamic strains. Herein, a synergistic structure with biphasic hierarchical networks and stable electrode interfaces is proposed to address these issues. The sensor employs a multilayer structure with polydimethylsiloxane (PDMS) substrate, carbon nanotube-doped PDMS (CNT-PDMS), and Ag film. Electrodes are fixed using a rigid island reinforced mortise and tenon joint formed with PDMS and CNT-PDMS. The Ag film dominates resistance during release, significantly reducing baseline drift. Strain-insensitive electrode interfaces further reduce baseline drift and noise. This optimized design ensures 99.999% resistance recovery without delay, even at high-speed (800 mm/min) and large (80%) strains. The sensor exhibits a high gauge factor of 55442, low detection limit (0.02%), and excellent stability (5000 cycles). With the designed algorithms, the single-channel sensor achieves 98.2% decoding accuracy for various gestures, demonstrating great potential for wearable electronics.

Flexible iontronics with super stretchability, toughness and enhanced conductivity based on collaborative design of high-entropy topology and multivalent ion-dipole interactions

All-solid-state ionic conductive elastomers (ASSICEs) are emerging as a promising alternative to hydrogels and ionogels in flexible electronics. Nevertheless, the synthesis of ASSICEs with concomitant mechanical robustness, superior ionic conductivity, and cost-effective recyclability poses a formidable challenge, primarily attributed to the inherent contradiction between mechanical strength and ionic conductivity. Herein, we present a collaborative design of high-entropy topological network and multivalent ion-dipole interaction for ASSICEs, and successfully mitigate the contradiction between mechanical robustness and ionic conductivity. Benefiting from the synergistic effect of this design, the coordination, de-coordination, and intrachain transfer of Li+ are effectively boomed. The resultant ASSICEs display exceptional mechanical robustness (breaking strength: 7.45 MPa, fracture elongation: 2621%, toughness: 107.19 MJ m-3) and impressive ionic conductivity (1.15 × 10-2 S m-1 at 25 °C). Furthermore, these ASSICEs exhibit excellent environmental stability (fracture elongation exceeding 1400% at 50 °C or -60 °C) and recyclability. Significantly, the application of these ASSICEs in a strain sensor highlights their potential in various fields, including human-interface communication, aerospace vacuum measurement, and medical balloon monitoring.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

Healable Ionic Conductors with Extremely Low-Hysteresis and High Mechanical Strength Enabled by Hydrophobic Domain-Locked Reversible Interactions

Extremely low hysteresis, high mechanical strength, superior toughness, and excellent healability are essential for stretchable ionic conductors to enhance their reliability and meet for cutting-edge applications. However, the fabrication of stretchable ionic conductors with such mutually exclusive properties remains challenging. Herein, extremely low-hysteresis and healable ionic conductors with a tensile strength of ≈8.9 MPa and toughness of ≈23.2 MJ m-3 are fabricated through the complexation of 4-carboxybenzaldehyde (CBA) grafted poly(vinyl alcohol) (PVA) (denoted as PVA-CBA) and poly (allylamine hydrochloride) (PAH) followed by acidification and ion-loading steps. The acidification step generates the PVA-CBA/PAH ionic conductors with in situ formed dynamic hydrophobic domains that lock and stabilize noncovalent interactions. This significantly minimizes the energy dissipation of the ionic conductors during cyclic mechanical loading (≤200% strain), resulting in ionic conductors with extremely low hysteresis (≈5%). The fractured ionic conductors can be healed at 60 °C to restore their original properties. Because of the extremely low hysteresis, the PVA-CBA/PAH ionic conductors show a highly stable and reproducible electrical response over 5000 uninterrupted loading-unloading cycles at a strain of 200%. The ionic conductor based sensors exhibit a high sensitivity to a wide range of strains (1-500%).

3D Printing of High Viscosity UV-Curable Resin for Highly Stretchable and Resilient Elastomer

Elastomers prepared via vat photopolymerizationus ually exhibit unsatisfied mechanical properties owing to their insufficient growth of molecular weight upon UV exposure. Increasing the weight ratio of oligomer in the resin system is an effective approach to enhance the mechanical properties, yet the viscosity of the UV-curable resin increases dramatically; this hinders its printing. In this study, a linear scan-based vat photopolymerization (LSVP) system which can print high-viscosity resins is implemented to 3D print the oligomer-dominated UV-curable resin via a dual-curing mechanism. A polyurethane methacrylate blocking oligomer is first synthesized and then mixed with a commercialized bifunctional oligomer, photoinitiator, and primary amine as a chain extender to prepare high-viscosity UV-curable resin for the LSVP system. The deblocked isocyanate is further crosslinked with a chain extender via thermal treatment to construct a highly entangled polymer chain network. The optimal thermal treatment parameters are investigated, and the resilience of the 3D-printed elastomer is evaluated through continuous tensile loading and unloading tests. Subsequently, complex structured elastomers are printed, exhibiting favorable mechanical durability without defects. The results obtained from this work will provide a reference for preparing elastomeric devices with excellent physical properties and expand the application scope of vat photopolymerization to new fields.