Recent Advances in Flexible Sensors and Their Applications

Mathematical modeling of flexible printed circuit configuration: a study in deformation and optimization

This manuscript offers an exhaustive analysis of Flexible Printed Circuits (FPCs), concentrating on enhancing their design to surmount two primary challenges. Firstly, it seeks to obviate contact with proximate components. Secondly, it aspires to adhere to pre-established curvature constraints. Predicated on the curvature properties of FPCs, we have developed a model adept at accurately forecasting FPC deformation under diverse conditions. Our inquiry entails a thorough examination of various FPC configurations, including bell, 'U', and 'S' shapes. Central to our methodology is the strategic optimization of FPC spatial arrangements, aiming to avert mechanical interference and control curvature, thus mitigating mechanical strain. This dual-faceted strategy is pivotal in enhancing the durability and operational reliability of FPCs, particularly in contexts demanding elevated flexibility and precision. Our research offers essential insights into the refinement of FPC design, skillfully addressing the complexities associated with curvature and physical interaction. Collectively, this study advocates a comprehensive framework for the design and implementation of FPCs, significantly advancing the field of contemporary electronics by ensuring these components meet the evolving demands of the industry.

Gel-Based Triboelectric Nanogenerators for Flexible Sensing: Principles, Properties, and Applications

The rapid development of the Internet of Things and artificial intelligence technologies has increased the need for wearable, portable, and self-powered flexible sensing devices. Triboelectric nanogenerators (TENGs) based on gel materials (with excellent conductivity, mechanical tunability, environmental adaptability, and biocompatibility) are considered an advanced approach for developing a new generation of flexible sensors. This review comprehensively summarizes the recent advances in gel-based TENGs for flexible sensors, covering their principles, properties, and applications. Based on the development requirements for flexible sensors, the working mechanism of gel-based TENGs and the characteristic advantages of gels are introduced. Design strategies for the performance optimization of hydrogel-, organogel-, and aerogel-based TENGs are systematically summarized. In addition, the applications of gel-based TENGs in human motion sensing, tactile sensing, health monitoring, environmental monitoring, human-machine interaction, and other related fields are summarized. Finally, the challenges of gel-based TENGs for flexible sensing are discussed, and feasible strategies are proposed to guide future research.

Robust, Efficient, and Recoverable Thermocells with Zwitterion-Boosted Hydrogel Electrolytes for Energy-Autonomous and Wearable Sensing

The rapid growth of flexible quasi-solid-state thermocells (TECs) provides a fresh way forward for wearable electronics. However, their insufficient mechanical strength and power output still hinder their further applications. This work demonstrates a one-stone-two-birds strategy to synergistically enhance the mechanical and thermoelectrochemical properties of the [Fe(CN)6]3-/4--based TECs. By introducing Hofmeister effect and multiple non-covalent interactions via betaine zwitterions, the mechanical strength of the conventional brittle gelatin hydrogel electrolytes is substantially improved from 50 to 440 kPa, with a high stretchability approaching 250 %. Meanwhile, the betaine zwitterions strongly affect the solvation structure of [Fe(CN)6]3- ions, thus enlarging the entropy difference and raising the thermoelectrochemical Seebeck coefficient from 1.47 to 2.2 mV K-1. The resultant quasi-solid-state TECs exhibit a normalized output power density of 0.48 mW m-2 K-2, showing a notable improvement in overall performance compared to their counterparts without zwitterion regulation. The intrinsic thermo-reversible property also allows the TECs to repeatedly self-recover through sol-gel transformations, ensuring reliable energy output and even recycling of TECs in case of extreme mechanical damages. An energy-autonomous smart glove consisting of eighteen individual TECs is further designed, which can simultaneously monitor the temperature of different positions on any touched object, demonstrating high potential in wearable applications.

Flexible Force Sensor Based on a PVA/AgNWs Nanocomposite and Cellulose Acetate

Nanocomposites are materials of special interest for the development of flexible electronic, optical, and mechanical devices in applications such as transparent conductive electrodes and flexible electronic sensors. These materials take advantage of the electrical, chemical, and mechanical properties of a polymeric matrix, especially in force sensors, as well as the properties of a conductive filler such as silver nanowires (AgNWs). In this work, the fabrication of a force sensor using AgNWs synthesized via the polyol chemical technique is presented. The nanowires were deposited via drop-casting in polyvinyl alcohol (PVA) to form the active (electrode) and resistive (nanocomposite) sensor films, with both films separated by a cellulose acetate substrate. The dimensions of the resulting sensor are 35 mm × 40 mm × 0.1 mm. The sensor shows an applied force ranging from 0 to 3.92 N, with a sensitivity of 0.039 N. The sensor stand-off resistance, exceeding 50 MΩ, indicates a good ability to detect changes in applied force without an external force. Additionally, studies revealed a response time of 10 ms, stabilization of 9 s, and a degree of hysteresis of 1.9%. The voltage response of the sensor under flexion at an angle of 85° was measured, demonstrating its functionality over a prolonged period. The fabricated sensor can be used in applications that require measuring pressure on irregular surfaces or systems with limited space, such as for estimating movement in robot joints.

Recent Advances in Wearable Healthcare Devices: From Material to Application

In recent years, the proliferation of wearable healthcare devices has marked a revolutionary shift in the personal health monitoring and management paradigm. These devices, ranging from fitness trackers to advanced biosensors, have not only made healthcare more accessible, but have also transformed the way individuals engage with their health data. By continuously monitoring health signs, from physical-based to biochemical-based such as heart rate and blood glucose levels, wearable technology offers insights into human health, enabling a proactive rather than a reactive approach to healthcare. This shift towards personalized health monitoring empowers individuals with the knowledge and tools to make informed decisions about their lifestyle and medical care, potentially leading to the earlier detection of health issues and more tailored treatment plans. This review presents the fabrication methods of flexible wearable healthcare devices and their applications in medical care. The potential challenges and future prospectives are also discussed.

Engineering of graphene-based composites with hexagonal boron nitride and PEDOT:PSS for sensing applications

A unique nanomaterial has been developed for sweat analysis, including glucose level monitoring. Simple resusable low-cost sensors from composite materials based on graphene, hexagonal boron nitride, and conductive PEDOT:PSS (poly(3,4-ethylenedioxythiophene)polystyrene sulfonate) polymer have been developed and fabricated via 2D printing on flexible substrates. The sensors were tested as biosensors using different water-based solutions. A strong increase in the current response (several orders of magnitude) was observed for aqua vapors or glucose solution vapors. This property is associated with the sorption capacity of graphene synthesized in a volume of plasma jets and thus having many active centers on the surface. The structure and properties of graphene synthesized in a plasma are different from those of graphene created by other methods. As a result, the current response for a wearable sensor is 3-5 orders of magnitude higher for the reference blood glucose concentration range of 4-14 mM. It has been found that the most promising sensor with the highest response was fabricated based on the graphene:PEDOT:PSS composite. The graphene:h-BN:PEDOT:PSS (h-BN is hexagonal boron nitride) sensors demonstrated a longer response and the highest response after the functionalization of the sensors with a glucose oxidase enzyme. The reusable wearable graphene:PEDOT:PSS glucose sensors on a paper substrate demonstrated a current response of 10-10 to 10-5 A for an operating voltage of 0.5 V and glucose range of 4-10 mM.

Highly Sensitive Paper-Based Force Sensors with Natural Micro-Nanostructure Sensitive Element

Flexible paper-based force sensors have garnered significant attention for their important potential applications in healthcare wearables, portable electronics, etc. However, most studies have only used paper as the flexible substrate for sensors, not fully exploiting the potential of paper's micro-nanostructure for sensing. This article proposes a novel approach where paper serves both as the sensitive element and the flexible substrate of force sensors. Under external mechanical forces, the micro-nanostructure of the conductive-treated paper will change, leading to significant changes in the related electrical output and thus enabling sensing. To demonstrate the feasibility and universality of this new method, the article takes paper-based capacitive pressure sensors and paper-based resistive strain sensors as examples, detailing their fabrication processes, constructing sensing principle models based on the micro-nanostructure of paper materials, and testing their main sensing performance. For the capacitive paper-based pressure sensor, it achieves a high sensitivity of 1.623 kPa-1, a fast response time of 240 ms, and a minimum pressure resolution of 4.1 Pa. As for the resistive paper-based strain sensor, it achieves a high sensitivity of 72 and a fast response time of 300 ms. The proposed new method offers advantages such as high sensitivity, simplicity in the fabrication process, environmental friendliness, and cost-effectiveness, providing new insights into the research of flexible force sensors.

Wearable Sensors as a Preoperative Assessment Tool: A Review

Surgery is a common first-line treatment for many types of disease, including cancer. Mortality rates after general elective surgery have seen significant decreases whilst postoperative complications remain a frequent occurrence. Preoperative assessment tools are used to support patient risk stratification but do not always provide a precise and accessible assessment. Wearable sensors (WS) provide an accessible alternative that offers continuous monitoring in a non-clinical setting. They have shown consistent uptake across the perioperative period but there has been no review of WS as a preoperative assessment tool. This paper reviews the developments in WS research that have application to the preoperative period. Accelerometers were consistently employed as sensors in research and were frequently combined with photoplethysmography or electrocardiography sensors. Pre-processing methods were discussed and missing data was a common theme; this was dealt with in several ways, commonly by employing an extraction threshold or using imputation techniques. Research rarely processed raw data; commercial devices that employ internal proprietary algorithms with pre-calculated heart rate and step count were most commonly employed limiting further feature extraction. A range of machine learning models were used to predict outcomes including support vector machines, random forests and regression models. No individual model clearly outperformed others. Deep learning proved successful for predicting exercise testing outcomes but only within large sample-size studies. This review outlines the challenges of WS and provides recommendations for future research to develop WS as a viable preoperative assessment tool.

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.

Recent Study Advances in Flexible Sensors Based on Polyimides

With the demand for healthy life and the great advancement of flexible electronics, flexible sensors are playing an irreplaceably important role in healthcare monitoring, wearable devices, clinic treatment, and so on. In particular, the design and application of polyimide (PI)-based sensors are emerging swiftly. However, the tremendous potential of PI in sensors is not deeply understood. This review focuses on recent studies in advanced applications of PI in flexible sensors, including PI nanofibers prepared by electrospinning as flexible substrates, PI aerogels as friction layers in triboelectric nanogenerator (TENG), PI films as sensitive layers based on fiber Bragg grating (FBG) in relative humidity (RH) sensors, photosensitive PI (PSPI) as sacrificial layers, and more. The simple laser-induced graphene (LIG) technique is also introduced in the application of PI graphitization to graphene. Finally, the prospect of PIs in the field of electronics is proposed in the review.

Untethered Soft Pneumatic Actuators with Embedded Multiple Sensing Capabilities

Pneumatic soft robot attracts extensive attention because of its own characteristics. It has great application potential in medical and other fields. Although the recent improvement of the soft robot shows great potentials for delicate manipulations, the development of completely untethered pneumatic intelligent soft robots remains challenging. This article introduces a novel type of untethered soft pneumatic actuator with embedded multiple sensing capabilities. The untethered drive of the soft pneumatic actuator is achieved by near-infrared-induced liquid-gas phase transition. In addition, a soft conductive resin was developed to make flexible sensors. Embedded flexible sensors enable bending and temperature sensing of soft actuators. With Digital Light Processing three-dimensional printing, the rapid fabrication of soft actuators and flexible sensors was realized. This article demonstrates the potential of the proposed untethered soft actuators with embedded multiple sensing capabilities as an important contribution to the research of completely untethered intelligent soft robots.

Morphic Sensors for Respiratory Parameters Estimation: Validation against Overnight Polysomnography

Effective monitoring of respiratory disturbances during sleep requires a sensor capable of accurately capturing chest movements or airflow displacement. Gold-standard monitoring of sleep and breathing through polysomnography achieves this task through dedicated chest/abdomen bands, thermistors, and nasal flow sensors, and more detailed physiology, evaluations via a nasal mask, pneumotachograph, and airway pressure sensors. However, these measurement approaches can be invasive and time-consuming to perform and analyze. This work compares the performance of a non-invasive wearable stretchable morphic sensor, which does not require direct skin contact, embedded in a t-shirt worn by 32 volunteer participants (26 males, 6 females) with sleep-disordered breathing who performed a detailed, overnight in-laboratory sleep study. Direct comparison of computed respiratory parameters from morphic sensors versus traditional polysomnography had approximately 95% (95 ± 0.7) accuracy. These findings confirm that novel wearable morphic sensors provide a viable alternative to non-invasively and simultaneously capture respiratory rate and chest and abdominal motions.

Carbon-Based Textile Sensors for Physiological-Signal Monitoring

As the focus on physical health increases, the market demand for flexible wearable sensors increases. Textiles combined with sensitive materials and electronic circuits can form flexible, breathable high-performance sensors for physiological-signal monitoring. Carbon-based materials such as graphene, carbon nanotubes (CNTs), and carbon black (CB) have been widely utilized in the development of flexible wearable sensors due to their high electrical conductivity, low toxicity, low mass density, and easy functionalization. This review provides an overview of recent advancements in carbon-based flexible textile sensors, highlighting the development, properties, and applications of graphene, CNTs, and CB for flexible textile sensors. The physiological signals that can be monitored by carbon-based textile sensors include electrocardiogram (ECG), human body movement, pulse and respiration, body temperature, and tactile perception. We categorize and describe carbon-based textile sensors based on the physiological signals they monitor. Finally, we discuss the current challenges associated with carbon-based textile sensors and explore the future direction of textile sensors for monitoring physiological signals.

Herbal molecule-mediated dual network hydrogels with adhesive and antibacterial properties for strain and pressure sensing

Multifunctional integration is the focus of hydrogel-based flexible sensors, and formation of a dual network (DN) could shed light on the fabrication of hydrogels with multifunctionality and enhanced properties. In this study, a DN hydrogel was fabricated by the self-assembly of herbal molecule glycyrrhizic acid (GA) as the first hydrogel network and subsequent photocrosslinking of methacrylated sodium alginate (SA-MA) to form the second network. Profiting from the good compatibility between the two hydrogel networks, the obtained DN hydrogels with a homogeneous porous microstructure were endowed with remarkably enlarged stretching (114.5%) and compression (74.4%) strains. In addition, they were demonstrated to display excellent bacteriostatic activity (>99.9%) against Escherichia coli and Staphylococcus aureus owing to the synergetic antibacterial effect of GA and SA-MA. The DN hydrogels as strain sensors possessed high sensitivity (GF = 1.39), linear sensing (R ² > 0.99), rapid response (180 ms), and good stability (1300 times) for human motion detection. Besides, the DN hydrogels could also be used to conduct pressure sensing such as application of heavy weights and even human pulses. All results suggest that the developed DN hydrogels have great potential in serving as epidermal and implantable flexible sensors for human health monitoring.

Wide-Range Flexible Capacitive Pressure Sensors Based on Dielectrics with Various Porosity

Wide-range flexible pressure sensors are in difficulty in research while in demand in application. In this paper, a wide-range capacitive flexible pressure sensor is developed with the foaming agent ammonium bicarbonate (NH₄HCO₃). By controlling the concentration of NH₄HCO₃ doped in the polydimethylsiloxane (PDMS) and repeating the curing process, pressure-sensitive dielectrics with various porosity are fabricated to expand the detection range of the capacitive pressure sensor. The shape and the size of each dielectric is defined by the 3D printed mold. To improve the dielectric property of the dielectric, a 1% weight ratio of multi-walled carbon nanotubes (MWCNTs) are doped into PDMS liquid. Besides that, a 5% weight ratio of MWCNTs is dispersed into deionized water and then coated on the electrodes to improve the contact state between copper electrodes and the dielectric. The laminated dielectric layer and two electrodes are assembled and tested. In order to verify the effectiveness of this design, some reference devices are prepared, such as sensors based on the dielectric with uniform porosity and a sensor with common copper electrodes. According to the testing results of these sensors, it can be seen that the sensor based on the dielectric with various porosity has higher sensitivity and a wider pressure detection range, which can detect the pressure range from 0 kPa to 1200 kPa and is extended to 300 kPa compared with the dielectric with uniform porosity. Finally, the sensor is applied to the fingerprint, finger joint, and knee bending test. The results show that the sensor has the potential to be applied to human motion detection.

Optimization of Piezoresistive Strain Sensors Based on Gold Nanoparticle Deposits on PDMS Substrates for Highly Sensitive Human Pulse Sensing

In this study, highly-sensitive piezoresistive strain sensors based on gold nanoparticle thin films deposited on a stretchable PDMS substrate by centrifugation were developed to measure arterial pulse waveform. By controlling carbon chain length of surfactants, pH value and particle density of the colloidal solutions, the gauge factors of nanoparticle thin film sensors can be optimized up to 677 in tensile mode and 338 in compressive mode, and the pressure sensitivity up to 350. Low pH and thin nanoparticle films produce positive influences to superior gauge factors. It has been demonstrated that nanoparticle thin film sensors on PDMS substrates were successfully applied to sense arterial pulses in different body positions, including wrist, elbow crease, neck, and chest.