Investigation of Laser-Induced Graphene (LIG) on a Flexible Substrate and Its Functionalization by Metal Doping for Gas-Sensing Applications

Graphene materials synthesized using direct laser writing (laser-induced graphene; LIG) make favorable sensor materials because of their large surface area, ease of fabrication, and cost-effectiveness. In particular, LIG decorated with metal nanoparticles (NPs) has been used in various sensors, including chemical sensors and electronic and electrochemical biosensors. However, the effect of metal decoration on LIG sensors remains controversial; hypotheses based on computational simulations do not always match the experimental results, and even the experimental results reported by different researchers have not been consistent. In the present study, we explored the effects of metal decorations on LIG gas sensors, with NO2 and NH3 gases as the representative oxidizing and reducing agents, respectively. To eliminate the unwanted side effects arising from metal salt residues, metal NPs were directly deposited via vacuum evaporation. Although the gas sensitivities of the sensors deteriorate upon metal decoration irrespective of the metal work function, in the case of NO2 gas, they improve upon metal decoration in the case of NH3 exposure. A careful investigation of the chemical structure and morphology of the metal NPs in the LIG sensors shows that the spontaneous oxidation of metal NPs with a low work function changes the behavior of the LIG gas sensors and that the sensors' behaviors under NO2 and NH3 gases follow different principles.

Highly Breathable, Stretchable, and Tailorable TPU Foam for Flexible Gas Sensors

Continuous real-time monitoring of air quality is of great significance in the realms of environmental monitoring, personal safety, and healthcare. Recently, flexible gas sensors have gained great popularity for their potential to be integrated into various smart wearable electronics and display devices. However, the development of gas sensors with superior sensitivity, breathability, and stretchability remains a challenge. Here, a new high porosity thermoplastic polyurethane (HP-TPU) foam was reported for gas sensors, which exhibited large three-dimensional network structures and excellent mechanical properties. The HP-TPU foam was achieved by using a simple steam-induced method, which was suitable for mass production. The unique structure endowed this foam with 77.5% porosity, 260% strain ability, and 0.45 MPa Young's modulus, which improved 35, 31, and 80%, respectively, compared to previously reported traditional TPU foam (T-TPU) prepared by the drying method. In addition, the foam presented high gas permeability (312 g/m-2, 24 h) and excellent stability, and it remained undamaged even after 2000 cycles at 70% strain. The sensing material was coated on a PET flexible interdigital electrode and sandwiched between two HP-TPU foam layers for a gas sensitivity test. Due to the easy diffusion of gas between the pores and contact with the sensing materials, the HP-TPU foam exhibited a significant reduction of 85% in average response time and 46% in average recovery time, compared to the T-TPU foam. A wearable sensing device, comprising sensing, data processing, and wireless transmission modules, was successfully developed to enable outdoor testing and achieved a detection range at the ppb level. Finally, the cytotoxicity test results confirmed that this flexible gas sensor did not harm human health. These results proved that this HP-TPU foam was an ideal matrix for the flexible gas sensor, exhibiting great application potential in the fields of seamless human-machine integration.

Flexible Sensor Film Based on Rod-Shaped SWCNT-Polypyrrole Nanocomposite for Acetone Gas Detection

A nanocomposite rod-shaped structure with a single-walled carbon nanotube (SWCNT) embedded in polypyrrole (PPy) doped with nonafluorobutanesulfonic acid (C4F), SWCNT/C4F-PPy, was synthesized using emulsion polymerization. The hybrid ink was then directly coated on a polyimide film interdigitated with the Cu/Ni/Au electrodes via a screen-printing technique to create a flexible film sensor. The sensor film showed a response of 1.72% at 25 °C/atmospheric pressure when acetone gas of 5 ppm was injected, which corresponds to almost 95% compared to the Si wafer-based array interdigitated with the Au electrode. Additionally, C4F was used as a hydrophobic dopant of PPy to improve the stability of humidity and to produce a highly sensitive film-type gas sensor that provides stable detection even in humid conditions.

2D PtSe2 Enabled Wireless Wearable Gas Monitoring Circuits with Distinctive Strain-Enhanced Performance

The application of 2D materials-based flexible electronics in wearable scenarios is limited due to performance degradation under strain fields. In contrast to its negative role in existing transistors or sensors, herein, we discover a positive effect of strain to the ammonia detection in 2D PtSe₂. Linear modulation of sensitivity is achieved in flexible 2D PtSe₂ sensors via a customized probe station with an in situ strain loading apparatus. For trace ammonia absorption, a 300% enhancement in room-temperature sensitivity (31.67% ppm^-1) and an ultralow limit of detection (50 ppb) are observed under 1/4 mm^-1 curvature strain. We identify three types of strain-sensitive adsorption sites in layered PtSe₂ and pinpoint that basal-plane lattice distortion contributes to better sensing performance resulting from reduced absorption energy and larger charge transfer density. Furthermore, we demonstrate state-of-the-art 2D PtSe₂-based wireless wearable integrated circuits, which allow real-time gas sensing data acquisition, processing, and transmission through a Bluetooth module to user terminals. The circuits exhibit a wide detection range with a maximum sensitivity value of 0.026 V·ppm^-1 and a low energy consumption below 2 mW.

Ultrasensitive Flexible Olfactory Receptor-Derived Peptide Sensor for Trimethylamine Detection by the Bending Connection Method

Trimethylamine (TMA) is a harmful gas that exists ubiquitously in the environment; therefore, the sensitive and specific monitoring of TMA is necessary. In this work, we prepared ultrasensitive flexible sensors for TMA detection based on single-walled carbon nanotubes (SWCNTs) and olfactory receptor-derived peptides (ORPs) on low-cost plastic substrates. A novel bending connection method was developed by intentionally bending the interdigitated electrodes with SWCNTs to form a three-dimensional structure during the ORP-connection process, leading to the exposure of more modification sites. The method showed ∼4.7-fold more effective connection amount of the ORPs to SWCNTs compared to the conventional flat-condition connection method. The flexible ORP-SWCNT sensors could significantly improve the limit of detection for gaseous TMA from the reported lowest limit of 10 parts per quadrillion (ppq) to 0.1 ppq. The flexible ORP sensors also exhibited excellent sensitivity to vaporized TMA standards and TMA generated by different kinds of foods under different bending conditions. The results showed that the bending connection method in this work was effective for ultrasensitive flexible ORP sensors and their associated applications.

Synergistic CNFs/CoS2/MoS2 Flexible Films with Unprecedented Selectivity for NO Gas at Room Temperature

Recently, room-temperature flexible gas sensors have been widely studied because they can operate without being heated and create low-cost, low-power-consumption devices with long-term stability. Here, by designing the active material composition and structure, we report an electrospun carbon nanofiber (CNF) network grafted by two-dimensional MoS₂ nanosheets and embedded CoS₂ nanoparticles, which serves as a flexible gas sensor for various toxic or hazardous gases working at room temperature. In particular, the CNFs/CoS₂/MoS₂ hybrid films exhibit very high selectivity toward NO over other gases including NO₂ and CH₄, with selectivity coefficients (|S_NO/S_NO2| and |S_NO/S_CH4|) as high as 43 and 42 (defined as the ratio of responses between two gases). The sensor shows a linear relationship in the gas concentration range of 1-100 ppm and a stable response during repeated bending. Theoretical calculations suggest that MoS₂ can be selectively n-doped by NO, while CoS₂ can effectively capture NO molecules, leading to enhanced selectivity and sensitivity. Our large-area flexible sensors made by synergistic design have potential applications in biological and environmental areas for low-cost, selective detection of toxic or targeted gases.

Three-Dimensional Graphene Hydrogel Decorated with SnO2 for High-Performance NO2 Sensing with Enhanced Immunity to Humidity

A facile, one-step hydrothermal route was exploited to prepare SnO₂-decorated reduced graphene oxide hydrogel (SnO₂/RGOH) with three-dimensional (3D) porous structures for NO₂ gas detection. Various material characterizations demonstrate the effective deoxygenation of graphene oxide and in situ growth of rutile SnO₂ nanoparticles (NPs) on 3D RGOH. Compared with the pristine RGOH, the SnO₂/RGOH displayed much lower limit of detection (LOD) and an order of magnitude higher sensitivity, revealing the distinct impact of SnO₂ NPs in improving the NO₂-sensing properties. An exceptional low theoretical LOD of 2.8 ppb was obtained at room temperature. The p-n heterojunction formed at the interface between RGOH and SnO₂ facilitates the charge transfer, improving both the sensitivity in NO₂ detection and the conductivity of hybrid material. Considering that existing SnO₂/RGO-based NO₂ sensors suffer from great vulnerability to humidity, here we employed integrated microheaters to effectively suppress the response to humidity, with nearly unimpaired response to NO₂, which boosted the selectivity. Notably, a flexible NO₂ sensor was constructed on a liquid crystal polymer substrate with endurance to mechanical deformation. This work indicates the feasibility of optimizing the gas-sensing performance of sensors by combining rational material hybridization, 3D structural engineering with temperature modulation.

Glass-Fabric Reinforced Ag Nanowire/Siloxane Composite Heater Substrate: Sub-10 nm Metal@Metal Oxide Nanosheet for Sensitive Flexible Sensing Platform

The development of flexible chemiresistors is imperative for real-time monitoring of air quality and/or human physical conditions without space constraints. However, critical challenges such as poor sensing characteristics, vulnerability under toxic chemicals, and weak reliability hinder their practical use. In this work, for the first time, an ultrasensitive flexible sensing platform is reported by assembling Pt loaded thin-layered (≈10 nm) SnO₂ nanosheets (Pt-SnO₂ NSs) based 2D sensing layers on Ag nanowires embedded glass-fabric reinforced vinyl-phenyl siloxane hybrid composite substrate (AgNW-GFRVPH film) as a heater. The thermally stable AgNW-GFRVPH film based heater is fabricated by free radical polymerization of vinyl groups in vinyl-phenyl oligosiloxane and phenyltris(dimethylvinylsiloxy)silane with Ag NW and glass-fabric, showing outstanding heat generation (≈200 °C), high dimensional stability (13 ppm °C^-1), and good thermal stability (≈350 °C). The Pt-SnO₂ NSs, which are synthesized by calcination of Sn precursor coated graphene oxide (GO) sheets and subsequent Pt functionalization, exhibit high mechanical flexibility and superior response (R_air/R_gas = 4.84) to 1 ppm level dimethyl sulfide. Taking these advantages, GO-templated oxide NSs combined with a highly stable AgNW-GFRVPH film heater exhibits the best dimethyl sulfide sensing performance compared to state-of-the-art flexible chemiresistors, enabling them as a superior flexible gas sensing platform.

Material-Independent Nanotransfer onto a Flexible Substrate Using Mechanical-Interlocking Structure

Nanowire-transfer technology has received much attention thanks to its capability to fabricate high-performance flexible nanodevices with high simplicity and throughput. However, it is still challenging to extend the conventional nanowire-transfer method to the fabrication of a wide range of devices since a chemical-adhesion-based nanowire-transfer mechanism is complex and time-consuming, hindering successful transfer of diverse nanowires made of various materials. Here, we introduce a material-independent mechanical-interlocking-based nanowire-transfer (MINT) method, fabricating ultralong and fully aligned nanowires on a large flexible substrate (2.5 × 2 cm²) in a highly robust manner. For the material-independent nanotransfer, we developed a mechanics-based nanotransfer method, which employs a dry-removable amorphous carbon (a-C) sacrificial layer between a vacuum-deposited nanowire and the underlying master mold. The controlled etching of the sacrificial layer enables the formation of a mechanical-interlocking structure under the nanowire, facilitating peeling off of the nanowire from the master mold robustly and reliably. Using the developed MINT method, we successfully fabricated various metallic and semiconductor nanowire arrays on flexible substrates. We further demonstrated that the developed method is well suited to the reliable fabrication of highly flexible and high-performance nanoelectronic devices. As examples, a fully aligned gold (Au) microheater array exhibited high bending stability (10⁶ cycling) and ultrafast (∼220 ms) heating operation up to ∼100 °C. An ultralong Au heater-embedded cuprous-oxide (Cu₂O) nanowire chemical gas sensor showed significantly improved reversible reaction kinetics toward NO₂ with 10-fold enhancement in sensitivity at 100 °C.

High-Sensitivity and Low-Power Flexible Schottky Hydrogen Sensor Based on Silicon Nanomembrane

High-performance and low-power flexible Schottky diode-based hydrogen sensor was developed. The sensor was fabricated by releasing Si nanomembrane (SiNM) and transferring onto a plastic substrate. After the transfer, palladium (Pd) and aluminum (Al) were selectively deposited as a sensing material and an electrode, respectively. The top-down fabrication process of flexible Pd/SiNM diode H₂ sensor is facile compared to other existing bottom-up fabricated flexible gas sensors while showing excellent H₂ sensitivity (Δ I/ I₀ > 700-0.5% H₂ concentrations) and fast response time (τ_10-90 = 22 s) at room temperature. In addition, selectivity, humidity, and mechanical tests verify that the sensor has excellent reliability and robustness under various environments. The operating power consumption of the sensor is only in the nanowatt range, which indicates its potential applications in low-power portable and wearable electronics.

Metal-Organic Framework-Templated PdO-Co3O4 Nanocubes Functionalized by SWCNTs: Improved NO2 Reaction Kinetics on Flexible Heating Film

Detection and control of air quality are major concerns in recent years for environmental monitoring and healthcare. In this work, we developed an integrated sensor architecture comprised of nanostructured composite sensing layers and a flexible heating substrate for portable and real-time detection of nitrogen dioxide (NO₂). As sensing layers, PdO-infiltrated Co₃O₄ hollow nanocubes (PdO-Co₃O₄ HNCs) were prepared by calcination of Pd-embedded Co-based metal-organic framework polyhedron particles. Single-walled carbon nanotubes (SWCNTs) were functionalized with PdO-Co₃O₄ HNCs to control conductivity of sensing layers. As a flexible heating substrate, the Ni mesh electrode covered with a 40 nm thick Au layer (i.e., Ni(core)/Au(shell) mesh) was embedded in a colorless polyimide (cPI) film. As a result, SWCNT-functionalized PdO-Co₃O₄ HNCs sensor exhibited improved NO₂ detection property at 100 °C, with high sensitivity (S) of 44.11% at 20 ppm and a low detection limit of 1 ppm. The accelerated reaction and recovery kinetics toward NO₂ of SWCNT-functionalized PdO-Co₃O₄ HNCs were achieved by generating heat on the Ni(core)/Au(shell) mesh-embedded cPI substrate. The SWCNT-functionalized porous metal oxide sensing layers integrated on the mechanically stable Ni(core)/Au(shell) mesh heating substrate can be envisioned as an essential sensing platform for realization of low-temperature operation wearable chemical sensor.

Metal Decoration Effects on the Gas-Sensing Properties of 2D Hybrid-Structures on Flexible Substrates

We have investigated the effects of metal decoration on the gas-sensing properties of a device with two-dimensional (2D) molybdenum disulfide (MoS₂) flake channels and graphene electrodes. The 2D hybrid-structure device sensitively detected NO₂ gas molecules (>1.2 ppm) as well as NH₃ (>10 ppm). Metal nanoparticles (NPs) could tune the electronic properties of the 2D graphene/MoS₂ device, increasing sensitivity to a specific gas molecule. For instance, palladium NPs accumulate hole carriers of graphene/MoS₂, electronically sensitizing NH₃ gas molecules. Contrarily, aluminum NPs deplete hole carriers, enhancing NO₂ sensitivity. The synergistic combination of metal NPs and 2D hybrid layers could be also applied to a flexible gas sensor. There was no serious degradation in the sensing performance of metal-decorated MoS₂ flexible devices before/after 5000 bending cycles. Thus, highly sensitive and endurable gas sensor could be achieved through the metal-decorated 2D hybrid-structure, offering a useful route to wearable electronic sensing platforms.