Force-Sensitive Interface Engineering in Flexible Pressure Sensors: A Review

Transfer Learning Enhanced Blood Pressure Monitoring Based on Flexible Optical Pulse Sensing Patch

Blood pressure (BP), a crucial health biomarker, is essential for detecting early indications of cardiovascular disease in routine monitoring and clinical surveillance of inpatients. However, conventional cuff-based BP measurements are limited in providing continuous comfort monitoring. Here, we present an optical pulse sensing patch for BP monitoring, which integrates three units of Gallium Nitride (GaN) optopairs with micronanostructured polydimethylsiloxane films to capture pulse waves. Multipoint pulse signals are transformed into BP and other cardiovascular indicators through machine learning. The transfer learning method is developed to calibrate the machine learning model with few training sets, simplifying the practical implementation. The developed sensing patch holds great potential for long-term, precise BP monitoring, enhancing clinical diagnosis, and management of cardiovascular diseases.

Highly compressible lamellar graphene/cellulose/sodium alginate aerogel via bidirectional freeze-drying for flexible pressure sensor

Graphene exhibits exceptional electrical properties, and aerogels made from it demonstrate high sensitivity when used in sensors. However, traditional graphene aerogels have poor biocompatibility and sustainability, posing potential environmental and health risks. Moreover, the stacking of their internal structures results in low compressive strength and fatigue resistance, which limits their further applications. In this study, green and sustainable cellulose nanofibers/sodium alginate/reduced graphene oxide aerogels (BCSRA) were synthesized, featuring a well-defined lamellar structure and a fiber cross-linked network, employing techniques such as bidirectional freeze-drying, ionic cross-linking, and thermal annealing. The unique internal architecture of BCSRA results in a compressive strength of up to 64.55 kPa at 70 % compression deformation and an extremely low density of merely 7.21 mg/cm3. Furthermore, BCSRA displays outstanding fatigue resistance, maintaining 82.17 % of its stress after 100 compression cycles at 70 % compressive strain and 86.99 % after 1000 cycles at 50 % compressive strain. Remarkably, when utilized as a flexible pressure sensor, BCSRA achieves a sensitivity of 5.71 kPa-1 and endures over 2200 cycles at 40 % compression, all while ensuring consistent electrical signal output. These properties underscore its significant potential for application in wearable flexible pressure sensors, capable of detecting various human movements.

Flexible Piezoresistive Film Pressure Sensor Based on Double-Sided Microstructure Sensing Layer

Flexible thin-film pressure sensors have garnered significant attention due to their applications in industrial inspection and human-computer interactions. However, due to their ultra-thin structure, these sensors often exhibit lower performance, including a narrow pressure response range and low sensitivity, which constrains their further application. The most commonly used microstructure fabrication methods are challenging to apply to ultra-thin functional layers and may compromise the structural stability of the sensors. In this study, we present a novel design of a film pressure sensor with a double-sided microstructure sensing layer by adopting the template method. By incorporating the double-sided microstructures, the proposed thin-film pressure sensor can simultaneously achieve a high sensitivity value of 5.5 kPa-1 and a wide range of 140 kPa, while maintaining a short response time of 120 ms and a low detection limit. This flexible film pressure sensor demonstrates considerable potential for distributed pressure sensing and industrial pressure monitoring applications.

Overview of 3D Printing Multimodal Flexible Sensors

With the growing demand for flexible sensing systems and precision engineering, there is an increasing need for sensors that can accurately measure and analyze multimode signals. 3D printing technology has emerged as a crucial tool in the development of multimodal flexible sensors due to its advantages in design flexibility and manufacturing complex structures. This paper provides a review of recent advancements in 3D printing technology within the field of multimode flexible sensors, with particular emphasis on the relevant working mechanisms involved in decoupling complex signals. First, the research status of 3D printed multimodal flexible sensors is discussed, including their responsiveness to different modal stimuli such as mechanics, temperature, and gas. Furthermore, it explores methods for decoupling multimodal signals through structural and material design, artificial intelligence, and other technologies. Finally, this paper summarizes current challenges such as limited material selection, difficulties in miniaturization integration, and crosstalk between multisignal outputs. It also looks forward to future research directions in this area.

Rational Design of Flexible Mechanical Force Sensors for Healthcare and Diagnosis

Over the past decade, there has been a significant surge in interest in flexible mechanical force sensing devices and systems. Tremendous efforts have been devoted to the development of flexible mechanical force sensors for daily healthcare and medical diagnosis, driven by the increasing demand for wearable/portable devices in long-term healthcare and precision medicine. In this review, we summarize recent advances in diverse categories of flexible mechanical force sensors, covering piezoresistive, capacitive, piezoelectric, triboelectric, magnetoelastic, and other force sensors. This review focuses on their working principles, design strategies and applications in healthcare and diagnosis, with an emphasis on the interplay among the sensor architecture, performance, and application scenario. Finally, we provide perspectives on the remaining challenges and opportunities in this field, with particular discussions on problem-driven force sensor designs, as well as developments of novel sensor architectures and intelligent mechanical force sensing systems.

All-Fabric Capacitive Pressure Sensors with Piezoelectric Nanofibers for Wearable Electronics and Robotic Sensing

Flexible pressure sensors are increasingly sought after for applications ranging from physiological signal monitoring to robotic sensing; however, the challenges associated with fabricating highly sensitive, comfortable, and cost-effective sensors remain formidable. This study presents a high-performance, all-fabric capacitive pressure sensor (AFCPS) that incorporates piezoelectric nanofibers. Through the meticulous optimization of conductive fiber electrodes and P(VDF-TrFE) nanofiber dielectric layers, the AFCPS exhibits exceptional attributes such as high sensitivity (4.05 kPa-1), an ultralow detection limit (0.6 Pa), an extensive detection range (∼100 kPa), rapid response time (<26 ms), and robust stability (>14,000 cycles). The sensor's porous structure enhances its compressibility, while its piezoelectric properties expedite charge separation, thereby increasing the interface capacitance and augmenting overall performance. These features are elucidated further through multiphysical field-coupling simulations and experimental testing. Owing to its comprehensive superior performance, the AFCPS has demonstrated its efficacy in monitoring human activity and physiological signals, as well as in discerning soft robotic grasping movements. Additionally, we have successfully implemented multiple AFCPS units as pressure sensor arrays to ascertain spatial pressure distribution and enable intelligent robotic gripping. Our research underscores the promising potential of the AFCPS device in wearable electronics and robotic sensing, thereby contributing significantly to the advancement of high-performance fabric-based sensors.

Research Progresses in Microstructure Designs of Flexible Pressure Sensors

Flexible electronic technology is one of the research hotspots, and numerous wearable devices have been widely used in our daily life. As an important part of wearable devices, flexible sensors can effectively detect various stimuli related to specific environments or biological species, having a very bright development prospect. Therefore, there has been lots of studies devoted to developing high-performance flexible pressure sensors. In addition to developing a variety of materials with excellent performances, the microstructure designs of materials can also effectively improve the performances of sensors, which has brought new ideas to scientists and attracted their attention increasingly. This paper will summarize the flexible pressure sensors based on material microstructure designs in recent years. The paper will mainly discuss the processing methods and characteristics of various sensors with different microstructures, and compare the advantages, disadvantages, and application scenarios of them. At the same time, the main application fields of flexible pressure sensors based on microstructure designs will be listed, and their future development and challenges will be discussed.

Interface Engineering in Chip-Scale GaN Optical Devices for Near-Hysteresis-Free Hydraulic Pressure Sensing

In this work, a compact, near-hysteresis-free hydraulic pressure sensor is presented through interface engineering in a GaN chip-scale optical device. The sensor consists of a monolithic GaN-on-sapphire device responsible for light emission and detection and a multilevel microstructured polydimethylsiloxane (PDMS) film prepared through a low-cost molding process using sandpaper as a template. The micro-patterned PDMS film functions as a pressure-sensing medium to effectively modulate the reflectance properties at the sapphire interface during pressure loading and unloading. The interface engineering endows the GaN optical device with near-hysteresis-free performance over a wide pressure range of up to 0-800 kPa. Verified by a series of experimental measurements on its dynamic responses, the tiny hydraulic sensor exhibits superior performance in hysteresis, stability, repeatability, and response time, indicating its considerable potential for a broad range of practical applications.

A Focused Review on the Flexible Wearable Sensors for Sports: From Kinematics to Physiologies

As an important branch of wearable electronics, highly flexible and wearable sensors are gaining huge attention due to their emerging applications. In recent years, the participation of wearable devices in sports has revolutionized the way to capture the kinematical and physiological status of athletes. This review focuses on the rapid development of flexible and wearable sensor technologies for sports. We identify and discuss the indicators that reveal the performance and physical condition of players. The kinematical indicators are mentioned according to the relevant body parts, and the physiological indicators are classified into vital signs and metabolisms. Additionally, the available wearable devices and their significant applications in monitoring these kinematical and physiological parameters are described with emphasis. The potential challenges and prospects for the future developments of wearable sensors in sports are discussed comprehensively. This review paper will assist both athletic individuals and researchers to have a comprehensive glimpse of the wearable techniques applied in different sports.

Digitized Construction of Iontronic Pressure Sensor with Self-Defined Configuration and Widely Regulated Performance

Flexible pressure sensors are essential components for wearable smart devices and intelligent systems. Significant progress has been made in this area, reporting on excellent sensor performance and fascinating sensor functionalities. Nevertheless, geometrical and morphological engineering of pressure sensors is usually neglected, which, however, is significant for practical application. Here, we present a digitized manufacturing methodology to construct a new class of iontronic pressure sensors with optionally defined configurations and widely modulated performance. These pressure sensors are composed of self-defined electrode patterns prepared by a screen printing method and highly tunable pressure-sensitive microstructures fabricated using 3D printed templates. Importantly, the iontronic pressure sensors employ an iontronic capacitive sensing mechanism based on mechanically regulating the electrical double layer at the electrolyte/electrode interfaces. The resultant pressure sensors exhibit high sensitivity (58 kPa^-1), fast response/recovery time (45 ms/75 ms), low detectability (6.64 Pa), and good repeatability (2000 cycles). Moreover, our pressure sensors show remarkable tunability and adaptability in device configuration and performance, which is challenging to achieve via conventional manufacturing processes. The promising applications of these iontronic pressure sensors in monitoring various human physiological activities, fabricating flexible electronic skin, and resolving the force variation during manipulation of an object with a robotic hand are successfully demonstrated.

Textile-Based Flexible Capacitive Pressure Sensors: A Review

Flexible capacitive pressure sensors have been widely used in electronic skin, human movement and health monitoring, and human-machine interactions. Recently, electronic textiles afford a valuable alternative to traditional capacitive pressure sensors due to their merits of flexibility, light weight, air permeability, low cost, and feasibility to fit various surfaces. The textile-based functional layers can serve as electrodes, dielectrics, and substrates, and various devices with semi-textile or all-textile structures have been well developed. This paper provides a comprehensive review of recent developments in textile-based flexible capacitive pressure sensors. The latest research progresses on textile devices with sandwich structures, yarn structures, and in-plane structures are introduced, and the influences of different device structures on performance are discussed. The applications of textile-based sensors in human wearable devices, robotic sensing, and human-machine interaction are then summarized. Finally, evolutionary trends, future directions, and challenges are highlighted.