Ultralightweight and 3D Squeezable Graphene-Polydimethylsiloxane Composite Foams as Piezoresistive Sensors

Chemical-Physical Synergistic Assembly of MXene/CNT Nanocoatings in Silicone Foams for Reliable Piezoresistive Sensing in Harsh Environments

Owing to their high sensitivity across a wide stress range, mechanical reliability, and rapid response time, flexible polymer foam piezoresistive sensors have been extensively used in various fields. The reliable application of these sensors under harsh environments, however, is severely limited by structural devastation and poor interfacial bonding between polymers and conductive nanoparticles. To address the above issues, robust MXene/CNT nanocoatings on the foam surface, where the chemical assembly of MXene nanosheets and the physical anchoring of CNTs lead to strong interfacial bonding, are designed and described, which endows foams with structural reliability and unexpected multi-functionalities without compromising their instinct properties. The optimized foam nanocomposites thus maintain outstanding wide-temperature flexibility (-60-210 °C) and elasticity (≈3% residual strain after 1000 cycles). Moreover, the nanocomposites display good sensitivity at a relatively wide stress range of 0-70% and remarkable stability under acidic and alkaline settings. Furthermore, the foams with exceptional fire resistance (UL-94 V-0 rating) can provide stable sensing behavior (over 300 cycles) even after being exposed to flames for 5 s, making them one of the most reliable sensing materials so far. Clearly, this work widens applications of flexible piezoresistive sensors based on silicone foam nanocomposites for various harsh environments.

Microbubble-based fabrication of resilient porous ionogels for high-sensitivity pressure sensors

High-sensitivity flexible pressure sensors have obtained extensive attention because of their expanding applications in e-skins and wearable medical devices for various disease diagnoses. As the representative candidate for these sensors, the iontronic microstructure has been widely proven to enhance sensation behaviors such as the sensitivity and limits of detection. However, the fast and tunable fabrication of ionic-porous sensing elastomers remains challenging because of the current template-dissolved or 3D printing methods. Here, we report a microbubble-based fabrication process that enables microporous and resilient-compliance ionogels for high-sensitivity pressure sensors. Periodic motion sliding results in a relative velocity between the imported airflow and the fluid solution, converts the airflow to microbubbles in the high-viscosity ionic fluid and promptly solidifies the fluid into a porous ionogel under ultraviolet exposure. The ultrahigh porosity of up to 95% endows the porous ionogel with superelasticity and a Young's modulus near 7 kPa. Due to the superelastic compliance and iontronic electrical double-layer effect, the porous ionogel packaged into two electrodes endows the pressure sensor with high sensitivity (684.4 kPa-1) over an ultrabroad range (~1 MPa) and a high-pressure resolution of 0.46%. Furthermore, the pressure sensor successfully captures high-yield broad-range signals from the fingertip low-pressure pulses (<1 kPa) to foot high-pressure activities (>500 kPa), even the grasping force of soft machine hands via an array-scanning circuit during object recognition. This microbubble-based fabrication process for porous ionogels paves the way for designing wearable sensors or permeable electronics to monitor and diagnose various diseases.

Recent Progress on Flexible Self-Powered Tactile Sensing Platforms for Health Monitoring and Robotics

Over the past decades, tactile sensing technology has made significant advances in the fields of health monitoring and robotics. Compared to conventional sensors, self-powered tactile sensors do not require an external power source to drive, which makes the entire system more flexible and lightweight. Therefore, they are excellent candidates for mimicking the tactile perception functions for wearable health monitoring and ideal electronic skin (e-skin) for intelligent robots. Herein, the working principles, materials, and device fabrication strategies of various self-powered tactile sensing platforms are introduced first. Then their applications in health monitoring and robotics are presented. Finally, the future prospects of self-powered tactile sensing systems are discussed.

Flexible highly-sensitive pressure sensor based on rGO/Fe nanowires composites for wearable human health detection

Flexible pressure sensors applied in wearable detection often face challenges, such as low sensitivity, large device size, poor flexibility, and long response time. This study aims to design and develop high-performance pressure-sensitive materials for wearable human detection applications. Using a sensitive layer composite and microstructural design, rGO/Fe nanowires (NWs) composites were proposed as the pressure-sensitive material. This approach yields a compact sensor with high flexibility, good mechanical properties, and excellent sensing performance. Firstly, rGO/Fe NWs composites were prepared by the Hummers method and an in situ reduction technique under a magnetic field. Secondly, the structural design, component construction, and sensing mechanism of the sensors were thoroughly investigated. Finally, the performance of the flexible pressure sensor was tested, and its application in the wearable field was explored. The results demonstrate that the sensor exhibits excellent performance with a good response to both large and small pressures within the range of 0-30 kPa, providing an effective method for wearable human health detection.

Research Progress of Flexible Piezoresistive Sensors Based on Polymer Porous Materials

Flexible piezoresistive sensors are in high demand in areas such as wearable devices, electronic skin, and human-machine interfaces due to their advantageous features, including low power consumption, excellent bending stability, broad testing pressure range, and simple manufacturing technology. With the advancement of intelligent technology, higher requirements for the sensitivity, accuracy, response time, measurement range, and weather resistance of piezoresistive sensors are emerging. Due to the designability of polymer porous materials and conductive phases, and with more multivariate combinations, it is possible to achieve higher sensitivity and lower detection limits, which are more promising than traditional flexible sensor materials. Based on this, this work reviews recent advancements in research on flexible pressure sensors utilizing polymer porous materials. Furthermore, this review examines sensor performance optimization and development from the perspectives of three-dimensional porous flexible substrate regulation, sensing material selection and composite technology, and substrate and sensing material structure design.

Recent progress in surface engineering methods and advanced applications of flexible polymeric foams

Polymeric foams, also known as three-dimensional (3D) polymeric sponges, are lightweight, flexible, compressible, and possess a high surface area compared with other bulk polymers. These sponges have traditionally been used for mattresses or seat cushions in homes, offices, aircraft, automobiles, and trains, and to insulate against heat, electricity, and noise. Recently, the demand for modern materials has expanded the application of polymeric foams to various high-value technologies, including in areas that need high flame retardancy, flame sensors, oil/water separation, metal adsorption, solar steam generation, piezoresistivity, electromagnetic interference shielding, thermal energy storage, catalysis, supercapacitors, batteries, and triboelectric energy harvesting. Proper modification of foams is a prerequisite for their use in high-value applications. Several new strategies for the surface coating of 3D porous foams and novel emerging applications have been recently developed. Therefore, in this review, current advances in the field of surface coating and the application of 3D polymeric foams are discussed. A brief background on 3D polymeric foams, including the unique properties and benefits of polymeric sponges and their routes of synthesis, is presented. Different coating strategies for polymeric sponges are discussed, and their advantages and drawbacks are highlighted. Different advanced applications of polymeric sponges, in conjunction with specific and detailed examples of the above-mentioned applications, are also described. Finally, challenges and potential applications related to the coating of polymeric foams are discussed. We envisage that this review will be useful to facilitate further research, promote continued efforts on the advanced applications mentioned above, and provide new stimuli for the design of novel polymeric sponges for future modern applications.

Recent advances in two-dimensional nanomaterials for sustainable wearable electronic devices

The widespread adoption of smart terminals has significantly boosted the market potential for wearable electronic devices. Two-dimensional (2D) nanomaterials show great promise for flexible, wearable electronics of next-generation electronic materials and have potential in energy, optoelectronics, and electronics. First, this review focuses on the importance of functionalization/defects in 2D nanomaterials, a discussion of different kinds of 2D materials for wearable devices, and the overall structure-property relationship of 2D materials. Then, in this comprehensive review, we delve into the burgeoning realm of emerging applications for 2D nanomaterial-based flexible wearable electronics, spanning diverse domains such as energy, medical health, and displays. A meticulous exploration is presented, elucidating the intricate processes involved in tailoring material properties for specific applications. Each research direction is dissected, offering insightful perspectives and dialectical evaluations that illuminate future trajectories and inspire fruitful investigations in this rapidly evolving field.

Development of Eco-Friendly and High-Strength Foam Sensors Based on Segregated Elastomer Composites with a Large Work Range and High Sensitivity

Achieving a high-strength piezoresistive foam with high sensitivity and a large workable range remains a major challenge. To realize these goals, we developed a facile, novel, and eco-friendly strategy for constructing segregated microcellular structures fabricated using coating, heat compression molding, and supercritical CO2 (ScCO2) foaming. The segregated poly(ether block amide) (PEBA)/carbon nanostructure (CNS) composites were fabricated via compression molding. This effectively improved the foamability and cell morphology of PEBA/CNS composites. Moreover, compared with the randomly distributed structure, the segregated structure also endowed the foams with better conductivity and sensing capability. Subsequently, the ScCO2 foaming was employed to fabricate segregated PEBA/CNS composite foams. The foaming gave composites a large compressibility and reduced their percolation threshold. Under 1 wt % CNS loading, via tuning the expansion ratio of foam from ∼2.1 to 4.1, the compression stress at 50% compression strain of foam varied from ∼3.3 to 0.5 MPa, and the conductivity changed from 4.89 × 10-3 to 1.93 × 10-6 s/m, implying a tunable conductivity. Additionally, the adjustable conductivity enabled the sensitivity of segregated composite foams to be regulated. The segregated PEBA/CNS foam (FCNS1-4.1) exhibited a good combination of high sensitivity (GF = 3.5), large work range (80% strain), and high compression strength (∼0.5 MPa at 50% strain) as well as a stable, reproducible, and durable sensing response under a low CNS content (∼0.11 vol %). Furthermore, the ΔI/I0 of FCNS1-4.1 (75.6% porosity) reached a high value of ∼810 and exhibited an ultrahigh sensitivity of ∼3706 (Δ I / I 0 ε ) from 60 to 80% strain. Moreover, the foam sensor could be used as a sensing function sole for monitoring diverse human motions. Therefore, the segregated PEBA/CNS composite foams with outstanding piezoresistive performances show promising potential applications in monitoring human motions as wearable electronics and provides a new design strategy for a new generation of foam sensors with high performance.

Boosting Sensitivity and Durability of Pressure Sensors Based on Compressible Cu Sponges by Strengthening Adhesion of "Rigid-Soft" Interfaces

The interface adhesion plays a key role between rigid metal and elastomer in compressible and stretchable conductors. However, the poor interfacial adhesion hinders their wide applications. To strengthen the interface adhesion, herein, a combination strategy of structure interlocking and polymer bridging is designed by introducing a method of subsurface-initiated atom transfer radical polymerization (sSI-ATRP). This method can make polymer brush root in polydimethylsiloxane (PDMS) subsurface, on this basis, metals further grow from subsurface to surface of PDMS via electroless deposition. As a result, the adhesive strength (≈2.5 MPa) between metal layer and PDMS elastomer is 4 times higher than that made by common polymer modification. As a demonstration, pressure sensor is constructed by using as-prepared compressible 3D Cu sponge as a top electrode and paper-based interdigited metal electrode as a bottom electrode. The device sensitivity can reach up to 961.2 kPa-1 and the durability can arrive at 3 000 cycles without degradation. Thus, this proposed interface-enhancement strategy for rigid-soft materials can significantly promote the performance of piezoresistive pressure sensors based on 3D conductive sponge. In the future, it would also be expanded to the fabrication of stretchable conductors and extensively applied in other flexible and wearable electronics.

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.

Fabric-like Electrospun PVAc-Graphene Nanofiber Webs as Wearable and Degradable Piezocapacitive Sensors

Flexible piezocapacitive sensors utilizing nanomaterial-polymer composite-based nanofibrous membranes offer an attractive alternative to more traditional piezoelectric and piezoresistive wearable sensors owing to their ultralow powered nature, fast response, low hysteresis, and insensitivity to temperature change. In this work, we propose a facile method of fabricating electrospun graphene-dispersed PVAc nanofibrous membrane-based piezocapacitive sensors for applications in IoT-enabled wearables and human physiological function monitoring. A series of electrical and material characterization experiments were conducted on both the pristine and graphene-dispersed PVAc nanofibers to understand the effect of graphene addition on nanofiber morphology, dielectric response, and pressure sensing performance. Dynamic uniaxial pressure sensing performance evaluation tests were conducted on the pristine and graphene-loaded PVAc nanofibrous membrane-based sensors for understanding the effect of two-dimensional (2D) nanofiller addition on pressure sensing performance. A marked increase in the dielectric constant and pressure sensing performance was observed for graphene-loaded spin coated membrane and nanofiber webs respectively, and subsequently the micro dipole formation model was invoked to explain the nanofiller-induced dielectric constant enhancement. The robustness and reliability of the sensor have been underscored by conducting accelerated lifetime assessment experiments entailing at least 3000 cycles of periodic tactile force loading. A series of tests involving human physiological parameter monitoring were conducted to underscore the applicability of the proposed sensor for IoT-enabled personalized health care, soft robotics, and next-generation prosthetic devices. Finally, the easy degradability of the sensing elements is demonstrated to emphasize their suitability for transient electronics applications.

Preparation of Thermoplastic Polyurethane/Multi-Walled Carbon Nanotubes Composite Foam with High Resilience Performance via Fused Filament Fabrication and CO2 Foaming Technique

Wearable flexible sensors with high sensitivity and wide detection range are applied in motion detection, medical diagnostic result and other fields, but poor resilience and hysteresis remain a challenge. In this study, a high-resilience foam sensor was prepared through a combination of additive manufacturing and green physical foaming method. The conductive filaments were prepared by using MWCNTs-modified TPU by the physical method of melt blending. Samples were prefabricated using the FFF printer and then saturated with CO2 in an autoclave before being removed and heated to foam. The composite foam effectively reduced residual strain, demonstrating the high resilience of the 3D-printed composite materials with a foam porous structure. The residual strain of the sample before foaming was >6% after a single cycle, and then gradually increased. The residual strain of the foamed samples is less than 5%. In addition, composite foam has high sensitivity and can monitor subtle pressure changes (0~40 kPa). The sensing performance of the composite foam was evaluated, and the current signal remained stable under different loading rates and small compression strains (2~5%). By using this highly resilient conductive composite material, a hierarchical shoe insole was designed that successfully detected human walking and running movements.

Three-Dimensional Printed Highly Porous and Flexible Conductive Polymer Nanocomposites with Dual-Scale Porosity and Piezoresistive Sensing Functions

Highly flexible, deformable, and ultralightweight structures are required for advanced sensing applications, such as wearable electronics and soft robotics. This study demonstrates the three-dimensional (3D) printing of highly flexible, ultralightweight, and conductive polymer nanocomposites (CPNCs) with dual-scale porosity and piezoresistive sensing functions. Macroscale pores are established by designing structural printing patterns with adjustable infill densities, while the microscale pores are developed by phase separation of the deposited polymer ink solution. A conductive polydimethylsiloxane solution is prepared by mixing polymer/carbon nanotubes with non-solvent and solvent phases. Silica nanoparticles are utilized to modify the rheological properties of the ink, making direct ink writing (DIW) feasible. 3D geometries with various structural infill densities and polymer concentrations are deposited using DIW. The solvent is evaporated during a stepping heat treatment, leading to non-solvent droplet nucleation and growth. The microscale cellular network is developed by removing the droplets and curing the polymer. Up to 83% tunable porosity is achieved by independently controlling the macro- and microscale porosity. The effect of macroscale/microscale porosity and printing nozzle sizes on the mechanical and piezoresistive behavior of the CPNC structures is explored. The electrical and mechanical tests demonstrate a durable, extremely deformable, and sensitive piezoresistive response without sacrificing mechanical performance. The flexibility and sensitivity of the CPNC structure are enhanced up to 900 and 67% with the development of dual-scale porosity. The application of the developed porous CPNCs as piezoresistive sensors for detecting human motion is also evaluated.

Self-Charging Piezo-Supercapacitor: One-Step Mechanical Energy Conversion and Storage

With the contemplations of ecological and environmental issues related to energy harvesting, piezoelectric nanogenerators (PNGs) may be an accessible, sustainable, and abundant elective wellspring of energy in the future. The PNGs' power output, however, is dependent on the mechanical energy input, which will be intermittent if the mechanical energy is not continuous. This is a fatal flaw for electronics that need continuous power. Here, a self-charging flexible supercapacitor (PSCFS) is successfully realized that can harvest sporadic mechanical energy, convert it to electrical energy, and simultaneously store power. Initially, chemically processed multimetallic oxide, namely, copper cobalt nickel oxide (CuCoNiO₄) is amalgamated within the poly(vinylidene fluoride) (PVDF) framework in different wt % to realize high-performance PNGs. The combination of CuCoNiO₄ as filler creates a notable electroactive phase inside the PVDF matrix, and the composite realized by combining 1 wt % CuCoNiO₄ with PVDF, coined as PNCU 1, exhibits the highest electroactive phase (>86%). Under periodic hammering (∼100 kPa), PNGs fabricated with this optimized composite film deliver an instantaneous voltage of ∼67.9 V and a current of ∼4.15 μA. Furthermore, PNG 1 is ingeniously integrated into a supercapacitor to construct PSCFS, using PNCU 1 as a separator and CuCoNiO₄ nanowires on carbon cloth (CC) as the positive and negative electrodes. The self-charging behavior of the rectifier-free storage device was established under bending deformation. The PSCFS device exhibits ∼845 mV from its initial open-circuit potential ∼35 mV in ∼220 s under periodic bending of 180° at a frequency of 1 Hz. The PSCFS can power up various portable electronic appliances such as calculators, watches, and LEDs. This work offers a high-performance, self-powered device that can be used to replace bulky batteries in everyday electronic devices by harnessing mechanical energy, converting mechanical energy from its environment into electrical energy.

Advances in Biodegradable Electronic Skin: Material Progress and Recent Applications in Sensing, Robotics, and Human-Machine Interfaces

The rapid growth of the electronics industry and proliferation of electronic materials and telecommunications technologies has led to the release of a massive amount of untreated electronic waste (e-waste) into the environment. Consequently, catastrophic environmental damage at the microbiome level and serious human health diseases threaten the natural fate of the planet. Currently, the demand for wearable electronics for applications in personalized medicine, electronic skins (e-skins), and health monitoring is substantial and growing. Therefore, "green" characteristics such as biodegradability, self-healing, and biocompatibility ensure the future application of wearable electronics and e-skins in biomedical engineering and bioanalytical sciences. Leveraging the biodegradability, sustainability, and biocompatibility of natural materials will dramatically influence the fabrication of environmentally friendly e-skins and wearable electronics. Here, the molecular and structural characteristics of biological skins and artificial e-skins are discussed. The focus then turns to the biodegradable materials, including natural and synthetic-polymer-based materials, and their recent applications in the development of biodegradable e-skin in wearable sensors, robotics, and human-machine interfaces (HMIs). Finally, the main challenges and outlook regarding the preparation and application of biodegradable e-skins are critically discussed in a near-future scenario, which is expected to lead to the next generation of biodegradable e-skins.

Silicone Rubber Based-Conductive Composites for Stretchable "All-in-One" Microsystems

Wearable electronics with development trends such as miniaturization, multifunction, and smart integration have become an important part of the Internet of Things (IoT) and have penetrated various sectors of modern society. To meet the increasing demands of wearable electronics in terms of deformability and conformability, many efforts have been devoted to overcoming the nonstretchable and poor conformal properties of traditional functional materials and endowing devices with outstanding mechanical properties. One of the promising approaches is composite engineering in which traditional functional materials are incorporated into the various polymer matrices to develop different kinds of functional composites and construct different functions of stretchable electronics. Herein, we focus on the approach of composite engineering and the polymer matrix of silicone rubber (SR), and we summarize the state-of-the-art details of silicone rubber-based conductive composites (SRCCs), including a summary of their conductivity mechanisms and synthesis methods and SRCC applications for stretchable electronics. For conductivity mechanisms, two conductivity mechanisms of SRCC are emphasized: percolation theory and the quantum tunneling mechanism. For synthesis methods of SRCCs, four typical approaches to synthesize different kinds of SRCCs are investigated: mixing/blending, infiltration, ion implantation, and in situ formation. For SRCC applications, different functions of stretchable electronics based on SRCCs for interconnecting, sensing, powering, actuating, and transmitting are summarized, including stretchable interconnects, sensors, nanogenerators, antennas, and transistors. These functions reveal the feasibility of constructing a stretchable all-in-one self-powered microsystem based on SRCC-based stretchable electronics. As a prospect, this microsystem is expected to integrate the functional sensing modulus, the energy harvesting modulus, and the process and response modulus together to sense and respond to environmental stimulations and human physiological signals.

Green syntheses of graphene and its applications in internet of things (IoT)-a status review

Internet of Things (IoT) is a trending technological field that converts any physical object into a communicable smarter one by converging the physical world with the digital world. This innovative technology connects the device to the internet and provides a platform to collect real-time data, cloud storage, and analyze the collected data to trigger smart actions from a remote location via remote notifications, etc. Because of its wide-ranging applications, this technology can be integrated into almost all the industries. Another trending field with tremendous opportunities is Nanotechnology, which provides many benefits in several areas of life, and helps to improve many technological and industrial sectors. So, integration of IoT and Nanotechnology can bring about the very important field of Internet of Nanothings (IoNT), which can re-shape the communication industry. For that, data (collected from trillions of nanosensors, connected to billions of devices) would be the 'ultimate truth', which could be generated from highly efficient nanosensors, fabricated from various novel nanomaterials, one of which is graphene, the so-called 'wonder material' of the 21st century. Therefore, graphene-assisted IoT/IoNT platforms may revolutionize the communication technologies around the globe. In this article, a status review of the smart applications of graphene in the IoT sector is presented. Firstly, various green synthesis of graphene for sustainable development is elucidated, followed by its applications in various nanosensors, detectors, actuators, memory, and nano-communication devices. Also, the future market prospects are discussed to converge various emerging concepts like machine learning, fog/edge computing, artificial intelligence, big data, and blockchain, with the graphene-assisted IoT field to bring about the concept of 'all-round connectivity in every sphere possible'.

A Review on the Applications of Graphene in Mechanical Transduction

A pressing need to develop low-cost, environmentally friendly, and sensitive sensors has arisen with the advent of the always-connected paradigm of the internet-of-things (IoT). In particular, mechanical sensors have been widely studied in recent years for applications ranging from health monitoring, through mechanical biosignals, to structure integrity analysis. On the other hand, innovative ways to implement mechanical actuation have also been the focus of intense research in an attempt to close the circle of human-machine interaction, and move toward applications in flexible electronics. Due to its potential scalability, disposability, and outstanding properties, graphene has been thoroughly studied in the field of mechanical transduction. The applications of graphene in mechanical transduction are reviewed here. An overview of sensor and actuator applications is provided, covering different transduction mechanisms such as piezoresistivity, capacitive sensing, optically interrogated displacement, piezoelectricity, triboelectricity, electrostatic actuation, chemomechanical and thermomechanical actuation, as well as thermoacoustic emission. A critical review of the main approaches is presented within the scope of a wider discussion on the future of this so-called wonder material in the field of mechanical transduction.

Poly(vinyl alcohol)/phosphoric acid gel electrolyte@polydimethylsiloxane sponge for piezoresistive pressure sensors

Piezoresistive pressure sensors based on flexible, ultrasensitive, and squeezable conductive sponges have recently attracted significant attention. However, the preparation of cost-effective conductive sponges with good stability and wide strain range for pressure sensing remains a challenge. Herein, a conductive poly(vinyl alcohol)/phosphoric acid gel electrolyte@polydimethylsiloxane (PVA/H₃PO₄@PDMS) composite was fabricated by impregnating a PDMS sponge into a PVA/H₃PO₄ gel electrolyte. The conductivity of the as-prepared sponges was determined using a gel electrolyte polymer film. The sponge exhibited good sensitivity of 0.1145 kPa^-1 in the low-pressure range (0-6.5 kPa), short response time (70 ms), and durability for over 2700 s (6000 cycles). The gauge factor of the PVA/H₃PO₄@PDMS sponge was 5.51, 1.49, and 0.33 at the strain range of 0-10%, 10-30%, and 30-80%, respectively. Based on these outstanding sensing performances, the sponges were applied for the detection of various human motions, such as vocal cord vibration, joint bending, respiratory rate, and pulse signal detection. Further, the sponge demonstrated their great potential in the fabrication of electronic skin and high-performance flexible wearable electronics. Therefore, the obtained PVA/H₃PO₄ gel electrolyte used as a sponge conductive coating material is a readily available and inexpensive material that can reduce the cost of composite materials for pressure sensing.

PDMS Sponges with Embedded Carbon Nanotubes as Piezoresistive Sensors for Human Motion Detection

Porous piezoresistive sensors offer promising flexible sensing functionality, such as human joint motion detection and gesture identification. Herein, a facile fabrication method is developed using a microwave-based rapid porogen removal technique for the manufacturing of porous nanocomposite sponges consisting of polydimethylsiloxane (PDMS) and well-dispersed carbon nanotubes (CNTs). The porogen amounts and CNT loadings are varied to tailor the porosity and electrical properties of the porous sensors. The sponges are characterized by a scanning electron microscope (SEM) to compare their microstructures, validate the high-quality CNT dispersion, and confirm the successful nanofiller embedding within the elastomeric matrix. Sponges with a 3 wt% CNT loading demonstrate the highest piezoresistive sensitivity. Experimental characterization shows that the sponges with low porosity have long durability and minimal strain rate dependence. Additionally, the developed sponges with 3 wt% CNTs are employed for the human motion detection using piezoresistive method. One experiment includes fingertip compression measurements on a prosthetic hand. Moreover, the sensors are attached to the chest, elbow, and knee of a user to detect breathing, running, walking, joint bending, and throwing motions.

High-sensitivity tactile sensor based on Ti2C-PDMS sponge for wireless human-computer interaction

Tremendous attention has been paid to high-performance flexible tactile sensors owing to their potential applications in bionic skin, wearable electronics, the Internet of Things, etc.However, the majority of pressure sensors require an intricately designed nanostructure requiring a high-cost complex manufacturing process. Therefore, the high-throughput and low-cost technology to produce high-sensitivity, flexible, pressure-sensitive materials with a large responding range is urgently needed. Herein, a novel flexible piezoresistive tactile sensor is fabricated based on the Ti₂C-PDMS sponge as the conductive elastomer. The sensor exhibits a high sensitivity of 279 kPa^-1in a wide pressure range (0-34.4 kPa). The response time is as fast as 0.45 s with excellent durability over 4,000 cycles. Moreover, a 16-pixel wireless sensor system is fabricated and a series of applications have been demonstrated, including real-time force perception and pressure morphology feedback, which promote the potential applications in the visualizing of pressure distribution, human-machine communication and wearable devices.

A flexible and highly sensitive pressure sensor based on three-dimensional electrospun carbon nanofibers

High-performance flexible pressure sensors with high sensitivity are important components of the systems for healthcare monitoring, human–machine interaction, and electronic skin. Herein, a flexible and highly sensitive pressure sensor composed of ferrosoferric oxide (Fe₃O₄)/carbon nanofibers (FeOCN) was fabricated using three-dimensional electrospinning and further heat treatment methods. The obtained pressure sensor demonstrates a wide working range (0–4.9 kPa) and a high sensitivity of 0.545 kPa⁻¹ as well as an ultralow detection limit of 6 Pa. Additionally, the pressure sensor exhibits a rapid response time, good stability, high hydrophobicity, and excellent flexibility. These merits endow the pressure sensor with the ability to precisely detect wrist pulse, phonation, breathing, and finger bending in real-time. Therefore, the FeOCN pressure sensor presents a promising application in real-time healthcare monitoring.

A three-dimensional electrospun carbon nanofiber network was used to measure press strains with high sensitivity.

Facile Fabrication of Flexible Pressure Sensor with Programmable Lattice Structure

Flexible pressure sensors have attracted intense attention because of their widespread applications in electronic skin, human-machine interfaces, and healthcare monitoring. Conductive porous structures are always utilized as active layers to improve the sensor sensitivities. However, flexible pressure sensors derived from traditional foaming techniques have limited structure designability. Besides, random pore distribution causes difference in structure and signal repeatability between different samples even in one batch, therefore limiting the batch production capabilities. Herein, we introduce a structure designable lattice structure pressure sensor (LPS) produced by bottom-up digital light processing (DLP) 3D printing technique, which is capable of efficiently producing 55 high fidelity lattice structure models in 30 min. The LPS shows high sensitivity (1.02 kPa^-1) with superior linearity over a wide pressure range (0.7 Pa to 160 kPa). By adjusting the design parameters such as lattice type and layer thickness, the electrical sensitivities and mechanical properties of LPS can be accurately controlled. In addition, the LPS endures up to 60000 compression cycles (at 10 kPa) without any obvious electrical signal degradation. This benefits from the firm carbon nanotubes (CNTs) coating derived from high-energy ultrasonic probe and the subsequent thermal curing process of UV-heat dual-curing photocurable resin. For practical applications, the LPS is used for real time pulse monitoring, voice recognition and Morse code communication. Furthermore, the LPS is also integrated to make a flexible 4 × 4 sensor arrays for detecting spatial pressure distribution and a flexible insole for foot pressure monitoring.

Superelastic, Fatigue-Resistant, and Flame-Retardant Spongy Conductor for Human Motion Detection against a Harsh High-Temperature Condition

The construction of wearable piezoresistive sensors with high elasticity, large gauge factor, and excellent durability in a harsh high-temperature environment is highly desired yet challenging. Here, a lightweight, superelastic, and fatigue-resistant spongy conductor was fabricated via a sponge-constrained network assembly, during which highly conductive graphene and flame-retardant montmorillonite were alternatively deposited on a three-dimensional melamine scaffold. The as-obtained spongy conductor exhibited a highly deformation-tolerant conductivity up to 80% strain and excellent fatigue resistance of 10,000 compressive cycles at 70% strain. As a result, the spongy conductor can readily work as a piezoresistive sensor and exhibited a high gauge factor value of ∼2.3 in a strain range of 60-80% and excellent durability under 60% strain for 10,000 cycles without sacrificing its piezoresistive performance. Additionally, the piezoresistive sensor showed great thermal stability up to 250 °C for more than 7 days and sufficient flame-retardant performance for at least 20 s. This lightweight, superelastic, and flame-retardant spongy conductor reveals tremendous potential in human motion detection against a harsh high-temperature environment.

Composited Gels from Nature Growing Scaffold: Synthesis, Properties, and Application

As a nature ultralight, well-aligned porous and anisotropy feedstock, cornstalk pith (CSP) has not been exploited for material design. Herein, we use CSP as substrate to prepare multifunctional elastic composite gels. First, CSP is pretreated by ferric chloride then immersed in an unsaturated monomer solution, following by a polymerization to form enhanced networks. The ferric ions act as junction sites for the combination between the polymer chains and the CSP matrix, therefore, dynamically reversible bonds are constructed. The bonds dissipate the compression force by breaking the dynamic bonds and reconstruct when the loading is removed. The reconstructed dynamic bonds endow an antifatigue performance of the prepared gels, in the cyclic compression test conducting 100 times with a 50% strain, and the gel holds a 94% elastic recovery. Furtherly, oil/water separation, cushioning system and biobased sensor are developed on the basis of what the matrix endows and what the reversible bonds exhibit. The preparation method in this study enriches a simply and high value-added method to utilize biobased material.

Enhanced Triboelectric Performance of Modified PDMS Nanocomposite Multilayered Nanogenerators

Recently, triboelectric nanogenerators (TENGs) have been widely utilized to address the energy demand of portable electronic devices by harvesting electrical energy from human activities or immediate surroundings. To increase the surface charge and surface area of negative TENGs, previous studies suggested several approaches such as micro-patterned arrays, porous structures, multilayer alignment, ion injections, ground systems and mixing of high dielectric constant materials. However, the preparation processes of these nanocomposite TENGs have been found to be complex and expensive. In this work, we report a simple, efficient and inexpensive modification of poly(dimethylsiloxane) (PDMS) using graphene nanoplatelets (GNPs) fillers and a Na₂CO₃ template. This GNP-PDMS was chemically bonded using 3-aminopropylethoxysilane (APTES) as a linker with an electrode multilayer made by layer-by-layer deposition of polyvinyl alcohol (PVA) and poly(4-styrene-sulfonic acid) (PSS)-stabilized GNP (denoted as [PVA/GNP-PSS]_n). A 33 wt.% Na₂CO₃ and 0.5 wt.% of GNP into a PDMS-based TENG gives an open-circuit voltage and short-circuit current density of up to ~270.2 V and ~0.44 μA/cm², which are ~8.7 and ~3.5 times higher than those of the pristine PDMS, respectively. The higher output performance is due to (1) the improved surface charge density, 54.49 μC/m², from oxygen functional moieties of GNP, (2) high surface roughness of the composite film, ~0.399 μm, which also increased the effective contact area, and (3) reduced charge leakage from chemical bonding of GNP-PDMS and [PVA/GNP-PSS]₃ via APTES. The proposed TENG fabrication process could be useful for the development of other high-performance TENGs.

Flexible Ecoflex®/Graphene Nanoplatelet Foams for Highly Sensitive Low-Pressure Sensors

The high demand for multifunctional devices for smart clothing applications, human motion detection, soft robotics, and artificial electronic skins has encouraged researchers to develop new high-performance flexible sensors. In this work, we fabricated and tested new 3D squeezable Ecoflex^® open cell foams loaded with different concentrations of graphene nanoplatelets (GNPs) in order to obtain lightweight, soft, and cost-effective piezoresistive sensors with high sensitivity in a low-pressure regime. We analyzed the morphology of the produced materials and characterized both the mechanical and piezoresistive response of samples through quasi-static cyclic compression tests. Results indicated that sensors infiltrated with 1 mg of ethanol/GNP solution with a GNP concentration of 3 mg/mL were more sensitive and stable compared to those infiltrated with the same amount of ethanol/GNP solution but with a lower GNP concentration. The electromechanical response of the sensors showed a negative piezoresistive behavior up to ~10 kPa and an opposite trend for the 10-40 kPa range. The sensors were particularly sensitive at very low deformations, thus obtaining a maximum sensitivity of 0.28 kPa^-1 for pressures lower than 10 kPa.

Development of an Ultra-Sensitive and Flexible Piezoresistive Flow Sensor Using Vertical Graphene Nanosheets

This paper suggests development of a flexible, lightweight, and ultra-sensitive piezoresistive flow sensor based on vertical graphene nanosheets (VGNs) with a mazelike structure. The sensor was thoroughly characterized for steady-state and oscillatory water flow monitoring applications. The results demonstrated a high sensitivity (103.91 mV (mm/s)^-1) and a very low-velocity detection threshold (1.127 mm s^-1) in steady-state flow monitoring. As one of many potential applications, we demonstrated that the proposed VGNs/PDMS flow sensor can closely mimic the vestibular hair cell sensors housed inside the semicircular canals (SCCs). As a proof of concept, magnetic resonance imaging of the human inner ear was conducted to measure the dimensions of the SCCs and to develop a 3D printed lateral semicircular canal (LSCC). The sensor was embedded into the artificial LSCC and tested for various physiological movements. The obtained results indicate that the flow sensor is able to distinguish minute changes in the rotational axis physical geometry, frequency, and amplitude. The success of this study paves the way for extending this technology not only to vestibular organ prosthesis but also to other applications such as blood/urine flow monitoring, intravenous therapy (IV), water leakage monitoring, and unmanned underwater robots through incorporation of the appropriate packaging of devices.

A Systematic Approach to the Design and Characterization of A Smart Insole for Detecting Vertical Ground Reaction Force (vGRF) in Gait Analysis

Gait analysis is a systematic study of human locomotion, which can be utilized in various applications, such as rehabilitation, clinical diagnostics and sports activities. The various limitations such as cost, non-portability, long setup time, post-processing time etc., of the current gait analysis techniques have made them unfeasible for individual use. This led to an increase in research interest in developing smart insoles where wearable sensors can be employed to detect vertical ground reaction forces (vGRF) and other gait variables. Smart insoles are flexible, portable and comfortable for gait analysis, and can monitor plantar pressure frequently through embedded sensors that convert the applied pressure to an electrical signal that can be displayed and analyzed further. Several research teams are still working to improve the insoles’ features such as size, sensitivity of insoles sensors, durability, and the intelligence of insoles to monitor and control subjects’ gait by detecting various complications providing recommendation to enhance walking performance. Even though systematic sensor calibration approaches have been followed by different teams to calibrate insoles’ sensor, expensive calibration devices were used for calibration such as universal testing machines or infrared motion capture cameras equipped in motion analysis labs. This paper provides a systematic design and characterization procedure for three different pressure sensors: force-sensitive resistors (FSRs), ceramic piezoelectric sensors, and flexible piezoelectric sensors that can be used for detecting vGRF using a smart insole. A simple calibration method based on a load cell is presented as an alternative to the expensive calibration techniques. In addition, to evaluate the performance of the different sensors as a component for the smart insole, the acquired vGRF from different insoles were used to compare them. The results showed that the FSR is the most effective sensor among the three sensors for smart insole applications, whereas the piezoelectric sensors can be utilized in detecting the start and end of the gait cycle. This study will be useful for any research group in replicating the design of a customized smart insole for gait analysis.

Piezoresistive Carbon Nanofiber-Based Cilia-Inspired Flow Sensor

Evolving over millions of years, hair-like natural flow sensors called cilia, which are found in fish, crickets, spiders, and inner ear cochlea, have achieved high resolution and sensitivity in flow sensing. In the pursuit of achieving such exceptional flow sensing performance in artificial sensors, researchers in the past have attempted to mimic the material, morphological, and functional properties of biological cilia sensors, to develop MEMS-based artificial cilia flow sensors. However, the fabrication of bio-inspired artificial cilia sensors involves complex and cumbersome micromachining techniques that lay constraints on the choice of materials, and prolongs the time taken to research, design, and fabricate new and novel designs, subsequently increasing the time-to-market. In this work, we establish a novel process flow for fabricating inexpensive, yet highly sensitive, cilia-inspired flow sensors. The artificial cilia flow sensor presented here, features a cilia-inspired high-aspect-ratio titanium pillar on an electrospun carbon nanofiber (CNF) sensing membrane. Tip displacement response calibration experiments conducted on the artificial cilia flow sensor demonstrated a lower detection threshold of 50 µm. Furthermore, flow calibration experiments conducted on the sensor revealed a steady-state airflow sensitivity of 6.16 mV/(m s⁻¹) and an oscillatory flow sensitivity of 26 mV/(m s⁻¹), with a lower detection threshold limit of 12.1 mm/s in the case of oscillatory flows. The flow sensing calibration experiments establish the feasibility of the proposed method for developing inexpensive, yet sensitive, flow sensors; which will be useful for applications involving precise flow monitoring in microfluidic devices, precise air/oxygen intake monitoring for hypoxic patients, and other biomedical devices tailored for intravenous drip/urine flow monitoring. In addition, this work also establishes the applicability of CNFs as novel sensing elements in MEMS devices and flexible sensors.

A Skin-Inspired Stretchable, Self-Healing and Electro-Conductive Hydrogel with A Synergistic Triple Network for Wearable Strain Sensors Applied in Human-Motion Detection

Keywords: nanocellulose; polyacrylic acid; polypyrrole; hydrogel; self-healing and conductive.