Ultrasensitive, flexible, and low-cost nanoporous piezoresistive composites for tactile pressure sensing

Toward flexible piezoresistive strain sensors based on polymer nanocomposites: a review on fundamentals, performance, and applications

The fundamentals, performance, and applications of piezoresistive strain sensors based on polymer nanocomposites are summarized herein. The addition of conductive nanoparticles to a flexible polymer matrix has emerged as a possible alternative to conventional strain gauges, which have limitations in detecting small strain levels and adapting to different surfaces. The evaluation of the properties or performance parameters of strain sensors such as the elongation at break, sensitivity, linearity, hysteresis, transient response, stability, and durability are explained in this review. Moreover, these nanocomposites can be exposed to different environmental conditions throughout their lifetime, including different temperature, humidity or acidity/alkalinity levels, that can affect performance parameters. The development of flexible piezoresistive sensors based on nanocomposites has emerged in recent years for applications related to the biomedical field, smart robotics, and structural health monitoring. However, there are still challenges to overcome in designing high-performance flexible sensors for practical implementation. Overall, this paper provides a comprehensive overview of the current state of research on flexible piezoresistive strain sensors based on polymer nanocomposites, which can be a viable option to address some of the major technological challenges that the future holds.

Porous nanocomposites with enhanced intrinsic piezoresistive sensitivity for bioinspired multimodal tactile sensors

In this work, we propose porous fluororubber/thermoplastic urethane nanocomposites (PFTNs) and explore their intrinsic piezoresistive sensitivity to pressure. Our experiments reveal that the intrinsic sensitivity of the PFTN-based sensor to pressure up to 10 kPa increases up to 900% compared to the porous thermoplastic urethane nanocomposite (PTN) counterpart and up to 275% compared to the porous fluororubber nanocomposite (PFN) counterpart. For pressures exceeding 10 kPa, the resistance-pressure relationship of PFTN follows a logarithmic function, and the sensitivity is 221% and 125% higher than that of PTN and PFN, respectively. With the excellent intrinsic sensitivity of the thick PFTN film, a single sensing unit with integrated electrode design can imitate human skin for touch detection, pressure perception and traction sensation. The sensing range of our multimodal tactile sensor reaches ~150 Pa, and it exhibits a linear fit over 97% for both normal pressure and shear force. We also demonstrate that an electronic skin, made of an array of sensing units, is capable of accurately recognizing complex tactile interactions including pinch, spread, and tweak motions.

A Review of Epidermal Flexible Pressure Sensing Arrays

In recent years, flexible pressure sensing arrays applied in medical monitoring, human-machine interaction, and the Internet of Things have received a lot of attention for their excellent performance. Epidermal sensing arrays can enable the sensing of physiological information, pressure, and other information such as haptics, providing new avenues for the development of wearable devices. This paper reviews the recent research progress on epidermal flexible pressure sensing arrays. Firstly, the fantastic performance materials currently used to prepare flexible pressure sensing arrays are outlined in terms of substrate layer, electrode layer, and sensitive layer. In addition, the general fabrication processes of the materials are summarized, including three-dimensional (3D) printing, screen printing, and laser engraving. Subsequently, the electrode layer structures and sensitive layer microstructures used to further improve the performance design of sensing arrays are discussed based on the limitations of the materials. Furthermore, we present recent advances in the application of fantastic-performance epidermal flexible pressure sensing arrays and their integration with back-end circuits. Finally, the potential challenges and development prospects of flexible pressure sensing arrays are discussed in a comprehensive manner.

Skin-Inspired Tactile Sensor on Cellulose Fiber Substrates with Interfacial Microstructure for Health Monitoring and Guitar Posture Feedback

Skin-inspired flexible tactile sensors, with interfacial microstructure, are developed on cellulose fiber substrates for subtle pressure applications. Our device is made of two cellulose fiber substrates with conductive microscale structures, which emulate the randomly distributed spinosum in between the dermis and epidermis layers of the human skin. The microstructures not only permit a higher stress concentration at the tips but also generate electrical contact points and change contact resistance between the top and bottom substrates when the pressure is applied. Meanwhile, cellulose fibers possessing viscoelastic and biocompatible properties are utilized as substrates to mimic the dermis and epidermis layers of the skin. The electrical contact resistances (ECR) are then measured to quantify the tactile information. The microstructures and the substrate properties are studied to enhance the sensors' sensitivity. A very high sensitivity (14.4 kPa^-1) and fast recovery time (approx. 2.5 ms) are achieved in the subtle pressure range (approx. 0-0.05 kPa). The device can detect subtle pressures from the human body due to breathing patterns and voice activity showing its potential for healthcare. Further, the guitar strumming and chord progression of the players with different skill levels are assessed to monitor the muscle strain during guitar playing, showing its potential for posture feedback in playing guitar or another musical instrument.

Soft CNT-Polymer Composites for High Pressure Sensors

Carbon−polymer composite-based pressure sensors have many attractive features, including low cost, easy integration, and facile fabrication. Previous studies on carbon−polymer composite sensors focused on very high sensitivities for low pressure ranges (10 s of kPa), which saturate quickly at higher pressures and thus are ill-suited to measure the high pressure ranges found in various applications, including those in underwater (>1 atm, 101 kPa) and industrial environments. Current sensors designed for high pressure environments are often difficult to fabricate, expensive, and, similarly to their low-pressure counterparts, have a narrow sensing range. To address these issues, this work reports the design, synthesis, characterization, and analysis of high-pressure TPU-MWCNT based composite sensors, which detect pressures from 0.5 MPa (4.9 atm) to over 10 MPa (98.7 atm). In this study, the typical approach to improve sensitivity by increasing conductive additive concentration was found to decrease sensor performance at elevated pressures. It is shown that a better approach to elevated pressure sensitivity is to increase sensor response range by decreasing the MWCNT weight percentage, which improves sensing range and resolution. Such sensors can be useful for measuring high pressures in many industrial (e.g., manipulator feedback), automotive (e.g., damping elements, bushings), and underwater (e.g., depth sensors) applications.

Beyond Chemistry: Tailoring Stiffness and Microarchitecture to Engineer Highly Sensitive Biphasic Elastomeric Piezoresistive Sensors

Carbon-based nanoparticles and conductive polymers are two classes of materials widely used in the production of three-dimensional (3D) piezoresistive sensors. One conductive polymer, poly(3,4-ethylenedioxythiophene):polystyrenesulfonate (PEDOT:PSS) has excellent stability and conductivity yet is limited in its application as a sensor, often existing upon a base, limiting its performance and potential. Despite much progress in the field of materials chemistry and polymer synthesis, one aspect we consider worthy of exploration is the impact that microstructure and stiffness may have on the sensitivity of 3D sensors. In this study, we report a strategy for fabricating biphasic electroactive sponges (EAS) that combine 3D porous PEDOT:PSS scaffolds possessing either an isotropic or anisotropic microarchitecture, infused with insulating elastomeric fillers of varying stiffness. When characterizing the electromechanical behavior of these EAS, a higher stiffness yields a higher strain gauge factor, with values as high as 387 for an isotropic microarchitecture infused with a stiff elastomer. The approach we describe is cost-effective and extremely versatile, by which one can fabricate piezoresistive sensors with adaptable sensitivity ranges and excellent high strain gauge factor with the underlying microarchitecture and insulant stiffness dictating this performance.

Cockroaches adjust body and appendages to traverse cluttered large obstacles

To traverse complex terrain, animals often transition between locomotor modes. It is well-known that locomotor transitions can be induced by switching in neural control circuits or driven by a need to minimize metabolic energetic cost. Recent work discovered that locomotor transitions in complex 3-D terrain cluttered with large obstacles can emerge from physical interaction with the environment controlled by the nervous system. For example, to traverse cluttered, stiff grass-like beams, the discoid cockroach often transitions from using a strenuous pitch mode pushing across to using a less strenuous roll mode rolling into and through the gaps, and this transition requires overcoming a potential energy barrier. Previous robotic physical modeling demonstrated that kinetic energy fluctuation of body oscillation from self-propulsion can help overcome the barrier and facilitate this transition. However, the animal was observed to transition even when the barrier still exceeded kinetic energy fluctuation. Here, we further studied whether and how the cockroach makes active adjustments to facilitate this transition to traverse cluttered beams. The animal repeatedly flexed its head and abdomen, reduced hind leg sprawl, and depressed one hind leg and elevated the other during the pitch-to-roll transition, which were absent when running on a flat ground. Using a refined potential energy landscape with additional degrees of freedom to model these adjustments, we found that head flexion did not substantially reduce the transition barrier, whereas leg sprawl reduction did so dramatically. We speculate that head flexion is for sensing the terrain to guide the transition via sensory feedback control.

Piezoelectric nanogenerators for personalized healthcare

The development of flexible piezoelectric nanogenerators has experienced rapid progress in the past decade and is serving as the technological foundation of future state-of-the-art personalized healthcare. Due to their highly efficient mechanical-to-electrical energy conversion, easy implementation, and self-powering nature, these devices permit a plethora of innovative healthcare applications in the space of active sensing, electrical stimulation therapy, as well as passive human biomechanical energy harvesting to third party power on-body devices. This article gives a comprehensive review of the piezoelectric nanogenerators for personalized healthcare. After a brief introduction to the fundamental physical science of the piezoelectric effect, material engineering strategies, device structural designs, and human-body centered energy harvesting, sensing, and therapeutics applications are also systematically discussed. In addition, the challenges and opportunities of utilizing piezoelectric nanogenerators for self-powered bioelectronics and personalized healthcare are outlined in detail.

Contact resistance based tactile sensor using covalently cross-linked graphene aerogels

A movable electrical contact between two materials is one of the most fundamental, simple, and common components in electronics that is used for binary control of a conducting path in an electrical circuit. Here, variable contact resistance between a highly elastic graphene aerogel and a rigid metal electrode is used for the analysis of non-binary pushing and pulling mechanical forces acting on the contact, enabling superior strain and pressure measurements. The variable contact resistance based electromechanical sensors demonstrate superfast, ultrasensitive and quantitative measurements of compressive and tensile stress from -1.18 MPa to 0.55 MPa. The sensors can operate over the temperature range of -60 to 100 °C, cover the whole skin and human motion range, and determine the weight of a grasped object. The measurement of such high forces has only been possible due to the high-temperature induced covalent cross-linking of graphene in the aerogel that provides high strength, durability, and fast response (<0.5 ms) to the sensing element. The study demonstrates the great potential of the contact resistance-controlled sensing, which enables high-precision and reliable measurement of strain and pressure over a remarkable large sensing range, providing new opportunities for applications in human-machine interfaces, robotics, flexible electronics, and haptic technology.

Ultrathin Superhydrophobic Flexible Tactile Sensors for Normal and Shear Force Discrimination

Flexible tactile sensors, with the ability to sense and even discriminate between different mechanical stimuli, can enable real-time and precise monitoring of dexterous and complex robotic motions. However, making them ultrathin and superhydrophobic for practical applications is still a great challenge. Here, superhydrophobic flexible tactile sensors with hierarchical micro- and nanostructures, that is, warped graphene nanosheets adhered to micron-height wrinkled surfaces, were constructed using ultrathin medical tape (40 μm) and graphene. The tactile sensor enables the discrimination of normal and shear forces and senses sliding friction and airflow. Moreover, the tactile sensor exhibits high sensitivity to normal and shear forces, extremely low detection limits (15 Pa for normal forces and 6.4 mN for shear forces), and cyclic robustness. Based on the abovementioned characteristics, the tactile sensor enables real-time and accurate monitoring of the robotic arm's motions, such as moving, gripping, and lifting, during the process of picking up objects. The superhydrophobicity even allows the sensor to monitor the motions of the robotic arm underwater in real time. Our tactile sensors have potential applications in the fields of intelligent robotics and smart prosthetics.

Flexible ferroelectric wearable devices for medical applications

Wearable electronics are becoming increasingly important for medical applications as they have revolutionized the way physiological parameters are monitored. Ferroelectric materials show spontaneous polarization below the Curie temperature, which changes with electric field, temperature, and mechanical deformation. Therefore, they have been widely used in sensor and actuator applications. In addition, these materials can be used for conversion of human-body energy into electricity for powering wearable electronics. In this paper, we review the recent advances in flexible ferroelectric materials for wearable human energy harvesting and sensing. To meet the performance requirements for medical applications, the most suitable materials and manufacturing techniques are reviewed. The approaches used to enhance performance and achieve long-term sustainability and multi-functionality by integrating other active sensing mechanisms (e.g. triboelectric and piezoresistive effects) are discussed. Data processing and transmission as well as the contribution of wearable piezoelectric devices in early disease detection and monitoring vital signs are reviewed.

Review on Conductive Polymer/CNTs Nanocomposites Based Flexible and Stretchable Strain and Pressure Sensors

In the last decade, significant developments of flexible and stretchable force sensors have been witnessed in order to satisfy the demand of several applications in robotic, prosthetics, wearables and structural health monitoring bringing decisive advantages due to their manifold customizability, easy integration and outstanding performance in terms of sensor properties and low-cost realization. In this paper, we review current advances in this field with a special focus on polymer/carbon nanotubes (CNTs) based sensors. Based on the electrical properties of polymer/CNTs nanocomposite, we explain underlying principles for pressure and strain sensors. We highlight the influence of the manufacturing processes on the achieved sensing properties and the manifold possibilities to realize sensors using different shapes, dimensions and measurement procedures. After an intensive review of the realized sensor performances in terms of sensitivity, stretchability, stability and durability, we describe perspectives and provide novel trends for future developments in this intriguing field.

A highly sensitive wearable flexible strain sensor based on polycrystalline MoS2 thin film

The present study investigates the piezoresistive properties of polycrystalline MoS₂ film for strain-sensing applications. The gauge factor (GF) of the flexible MoS₂ device (MoS₂/PET) has been calculated to be 102 ± 5 in the stress range from ~7 MPa to ~14 MPa. In addition, to improve the sensing stress range, the flexible strain sensors are encapsulated by SU-8. The effect of encapsulation layer thickness is reflected in the GF, which is attributed to the shifting of the neutral axis. However, the calculated GF is constant in the higher stress range, 80 ± 2 and 12 ± 1 for 2 μm and 10 μm thick SU-8, respectively. Herein, we report a cost-effective and scalable approach to fabricate large-area polycrystalline MoS₂-based flexible sensors for a wider stress range. The encapsulated devices remained undistorted and intact for stress values beyond 14 MPa. Further, we demonstrate the durability of the fabricated sensors with body movements, such as hand gestures, for all the three types of strain sensor.

Development of Fully Flexible Tactile Pressure Sensor with Bilayer Interlaced Bumps for Robotic Grasping Applications

Flexible tactile sensors have been utilized in intelligent robotics for human-machine interaction and healthcare monitoring. The relatively low flexibility, unbalanced sensitivity and sensing range of the tactile sensors are hindering the accurate tactile information perception during robotic hand grasping of different objects. This paper developed a fully flexible tactile pressure sensor, using the flexible graphene and silver composites as the sensing element and stretchable electrodes, respectively. As for the structural design of the tactile sensor, the proposed bilayer interlaced bumps can be used to convert external pressure into the stretching of graphene composites. The fabricated tactile sensor exhibits a high sensing performance, including relatively high sensitivity (up to 3.40% kPa-1), wide sensing range (200 kPa), good dynamic response, and considerable repeatability. Then, the tactile sensor has been integrated with the robotic hand finger, and the grasping results have indicated the capability of using the tactile sensor to detect the distributed pressure during grasping applications. The grasping motions, properties of the objects can be further analyzed through the acquired tactile information in time and spatial domains, demonstrating the potential applications of the tactile sensor in intelligent robotics and human-machine interfaces.

Giant Resistivity Change of Transparent ZnO/Muscovite Heteroepitaxy

The piezoresistive effect has shown a remarkable potential for mechanical sensor applications and been sought for its excellent performance. A great attention was paid to the giant piezoresistive effect and sensitivity delivered by silicon-based nanostructures. However, low thermal stability and complicated fabrication process hinder their practical applications. To overcome these issues and enhance the functionalities, we envision the substantial piezopotential in a zinc oxide (ZnO)/muscovite (mica) heteroepitaxy system based on theoretical consideration and realize it in practice. High piezoresistive effect with giant change of resistivity (-80 to 240%) and large gauge factor (>1000) are demonstrated through mechanical bending. The detailed features of heteroepitaxy, electrical transport, and strain are probed to understand the mechanism of such a giant resistivity change. In addition, a bending model is established to reveal the distribution of strain. Finally, we demonstrate a flex sensor featuring high sensitivity, optical transparency, and two-segment sensing with a great potential toward practical applications. Such an oxide heteroepitaxy exhibits excellent piezoresistive properties and mechanical flexibility. In the near future, the importance of flex sensors will emerge because of the precise control in the automation industries, and our results lead to a new design in the field of flex sensors.

Advances in Rational Design and Materials of High-Performance Stretchable Electromechanical Sensors

Stretchable and wearable sensor technology has attracted significant interests and created high technological impact on portable healthcare and smart human-machine interfaces. Wearable electromechanical systems are an important part of this technology that has recently witnessed tremendous progress toward high-performance devices for commercialization. Over the past few years, great attention has been paid to simultaneously enhance the sensitivity and stretchability of the electromechanical sensors toward high sensitivity, ultra-stretchability, low power consumption or self-power functionalities, miniaturisation as well as simplicity in design and fabrication. This work presents state-of-the-art advanced materials and rational designs of electromechanical sensors for wearable applications. Advances in various sensing concepts and structural designs for intrinsic stretchable conductive materials as well as advanced rational platforms are discussed. In addition, the practical applications and challenges in the development of stretchable electromechanical sensors are briefly mentioned and highlighted.

Multimodal Sensing with a Three-Dimensional Piezoresistive Structure

Sensors that reproduce the complex characteristics of cutaneous receptors in the skin have important potential in the context of artificial systems for controlled interactions with the physical environment. Multimodal responses with high sensitivity and wide dynamic range are essential for many such applications. This report introduces a simple, three-dimensional type of microelectromechanical sensor that incorporates monocrystalline silicon nanomembranes as piezoresistive elements in a configuration that enables separate, simultaneous measurements of multiple mechanical stimuli, such as normal force, shear force, and bending, along with temperature. The technology provides high sensitivity measurements with millisecond response times, as supported by quantitative simulations. The fabrication and assembly processes allow scalable production of interconnected arrays of such devices with capabilities in spatiotemporal mapping. Integration with wireless data recording and transmission electronics allows operation with standard consumer devices.

Scalable Manufactured Self-Healing Strain Sensors Based on Ion-Intercalated Graphene Nanosheets and Interfacial Coordination

Desirable mechanical strength and self-healing performance are very important to highly sensitive and stretchable sensors to meet their practical applications. However, balancing these two key performance parameters is still a great challenge. Herein, we present a simple, large-scale, and cost-efficient route to fabricate autonomously self-healing strain sensors with satisfactory mechanical properties. Specifically, ion-intercalated mechanical milling was utilized to realize the large-scale preparation of graphene nanosheets (GNs). Then, a well-organized GN-nanostructured network was constructed in a rubber matrix based on interfacial metal-ligand coordination. The resultant nanocomposites show desirable mechanical properties (∼5 times higher than that of control sample without interfacial coordination), excellent self-healing performance (even healable in various harsh conditions, for example, underwater, at subzero temperature or exposed in acidic and alkaline conditions), and ultrahigh sensitivity (gauge factor ≈ 45 573.1). The elaborately designed strain sensors offer a feasible approach for the scalable production of self-healing strain-sensing devices, making it promising for further applications, including artificial skin, smart robotics, and other electrical devices.