Design, Fabrication, and Optimization of a Printed Ag Nanoparticle-Based Flexible Capacitive Sensor for Automotive IVI Bezel Display Applications

Since printed capacitive sensors provide better sensing performance, they can be used in automotive bezel applications. It is necessary to fabricate such sensors and apply an optimization approach for choosing the optimal sensor pattern. In the present work, an effort was made to formulate interdigitated pattern-printed Silver (Ag) electrode flexible sensors and adopt the Taguchi Grey Relational (TGR)-based optimization approach to enhance the flexible sensor's panel for enhanced automobile infotainment applications. The optimization technique was performed to derive better design considerations and analyze the influence of the sensor's parameters on change in capacitance when touched and production cost. The fabricated flexible printed sensors can provide better sensing properties. A design pattern which integrates an overlap of 15 mm, an electrode line width of 0.8 mm, and an electrode gap 0.8 mm can produce a higher change in capacitance and achieve a lower weight. The overlap has a greater influence on sensor performance owing to its optimization of spatial interpolation.

Cold Atmospheric Plasma-Assisted Direct Deposition of Polypyrrole-Ag Nanocomposites for Flexible Electronic Sensors

Conductive polymers and their composite materials have attracted considerable interest due to their potential applications in sensors, actuators, drug delivery systems, and energy storage devices. Despite their wide range of applications, many challenges remain primarily with respect to the complex synthesis and time-consuming manufacturing steps that are often required in the fabrication process of various devices with conductive polymers. Here, we demonstrate the novel use of cold atmospheric plasma (CAP)-assisted deposition technologies as a solvent-free and scalable approach for in situ polymerization and direct deposition of conductive polypyrrole-silver (PPy-Ag) nanocomposites onto the desired substrates under atmospheric conditions. In this study, a systematic approach with different precursor composition mixtures containing pyrrole as the monomer and AgNO₃ as the photoinitiator was investigated to assess the effect of precursor composition on the final chemical, electrical, and mechanical properties of the PPy-Ag nanocomposite thin-film coatings which were characterized by scanning electron microscopy, Fourier transform infrared spectroscopy, X-ray diffraction, and cyclic bending tests. The characterizations indicated the possibility of fabricating PPy-Ag nanocomposite films with tunable degrees of polymerization and Ag nanoparticle loading by simply varying the percentage of AgNO₃ in precursor composition mixtures. Finally, as a proof of concept, the potential use of the PPy-Ag nanocomposite films with different Ag nanoparticle loading percentages was assessed for humidity sensing by measuring their level of change in electrical resistance in the relative humidity range of 12-60%. It is envisioned that the developed CAP-assisted deposition technology can provide a new stepping stone toward scalable additive manufacturing of various functional nanocomposite films for different low-cost and flexible electronic applications.

Fabrication of Low-Cost Resistance Temperature Detectors and Micro-Heaters by Electrohydrodynamic Printing

EHD printing is an advanced deposition technology that is commonly utilized for the direct manufacture of electrical devices. In this study, meander-type resistive electrodes consisting of silver nanoparticles were printed directly on rigid glass and flexible polyethylene terephthalate (PET) substrates. High-resolution patterns of ≈50 µm linewidth were successfully printed on untreated surfaces utilizing a bigger nozzle of 100 µm inner diameter after improving the experimental settings. The manufactured electrodes were evaluated and used as Resistance Temperature Detectors (RTDs) and micro-heaters in a systematic manner. The temperature sensors performed well, with a Temperature Coefficient of Resistivity (TCRs) of 11.5 ×10-3/°C and 13.3 ×10-3/°C, for glass and PET substrates, respectively, throughout a wide temperature range of 100 °C and 90 °C. Furthermore, the RTDs had a quick response and recovery time, as well as minimal hysteresis. The electrodes' measured sensitivities as micro-heaters were 3.3 °C/V for glass and 6.8 °C/V for PET substrates, respectively. The RTDs were utilized for signal conditioning in a Wheatstone bridge circuit with a self-heating temperature of less than 1 °C as a practical demonstration. The micro-heaters have a lot of potential in the field of soft wearable electronics for biomedical applications, while the extremely sensitive RTDs have a lot of potential in industrial situations for temperature monitoring.

Rotation Grids for Improved Electrical Properties of Inkjet-Printed Strain Gauges

We report an image data driven approach for inkjet printing (IJP) to improve the electrical properties of printed metallic strain gauges (SGs). The examined SGs contain narrow conducting paths of multiple orientations and therefore suffer from two challenges: 1. The printing direction of inkjet printed conducting paths has an impact on film formation and electrical properties. 2. A loss-free rotation algorithm for IJP image data is lacking. New ways of IJP image data processing are required to compensate for quality-reducing effects. Novel grid types in terms of loss-free rotation algorithms are introduced. For this purpose, a new grid (e.g., 45° tilted) with a different grid constant is placed over a given pixel grid in such a way that all cell centers of the given pixel grid can be transferred to the rotated grid. Via straightening the tilt, the image data is rotated without interpolation and information loss. By applying these methods to measurement gratings of a full bridge with two perpendicular grating orientations, the influence on the manufacturing quality is investigated. It turns out that the electrical detuning of full bridges can be reduced by one order of magnitude compared to state-of-the-art printing by using so-called diagonal rotation grids.

Printed Potentiometric Nitrate Sensors for Use in Soil

Plant-available nitrogen, often in the form of nitrate, is an essential nutrient for plant growth. However, excessive nitrate in the environment and watershed has harmful impacts on natural ecosystems and consequently human health. A distributed network of nitrate sensors could help to quantify and monitor nitrogen in agriculture and the environment. Here, we have developed fully printed potentiometric nitrate sensors and characterized their sensitivity and selectivity to nitrate. Each sensor comprises an ion-selective electrode and a reference electrode that are functionalized with polymeric membranes. The sensitivity of the printed ion-selective electrodes was characterized by measuring their potential with respect to a commercial silver/silver chloride reference electrode in varying concentrations of nitrate solutions. The sensitivity of the printed reference electrodes to nitrate was minimized with a membrane containing polyvinyl butyral (PVB), sodium chloride, and sodium nitrate. Selectivity studies with sulphate, chloride, phosphate, nitrite, ammonium, calcium, potassium, and magnesium showed that high concentrations of calcium can influence sensor behavior. The printed ion-selective and reference electrodes were combined to form a fully printed sensor with sensitivity of −48.0 ± 3.3 mV/dec between 0.62 and 6200 ppm nitrate in solution and −47 ± 4.1 mV/dec in peat soil.

Flexible Hybrid Electrodes for Continuous Measurement of the Local Temperature in Long-Term Wounds

Long-term wounds need a continuous assessment of different biophysical parameters for their treatment, and there is a lack of affordable biocompatible devices capable of obtaining that uninterrupted flow of data. A portable prototype that allows caregivers to know the local temperature behavior of a long-term wound over time and compare it with different reference zones has been developed. Alternative flexible substrates, screen-printing techniques, polymeric inks, and an embedded system have been tested to achieve potential indicators of the status and evolution of chronic wounds. The final system is formed by temperature sensors attached to a flexible and stretchable medical-grade substrate, where silver conductive tracks have been printed as interconnections with the data-acquisition unit. In addition, a specific datalogger has been developed for this system. The whole set will enable health personnel to acquire the temperature of the wound and its surroundings in order to make decisions regarding the state and evolution of the wound.

Sustainable Printed Electrochemical Platforms for Greener Analytics

The development of miniaturized electrochemical platforms holds considerable importance for the in situ analytical monitoring of clinical, environmental, food, and forensic samples. However, it is crucial to pay attention to the sustainability of materials chosen to fabricate these devices, in order to decrease the amount and the impact of waste coming from their production and use. In the framework of a circular economy and an environmental footprint reduction, the electrochemical sensor production technology must discover the potentiality of innovative approaches based on techniques and materials that can satisfy the needs of environmental-friendly and greener analytics. The aim of this review is to describe some of the printing technologies most used for sensor production, including screen-printing, inkjet-printing, and 3D-printing, and the low-impact materials that are recently proposed for these techniques, such as polylactic acid, cellulose, silk proteins, biochar.

SmartTags: IoT Product Passport for Circular Economy Based on Printed Sensors and Unique Item-Level Identifiers

In this paper, we present a method that facilitates Internet of Things (IoT) for building a product passport and data exchange enabling the next stage of the circular economy. SmartTags based on printed sensors (i.e., using functional ink) and a modified GS1 barcode standard enable unique identification of objects on a per item-level (including Fast-Moving Consumer Goods-FMCG), collecting, sensing, and reading of parameters from environment as well as tracking a products' lifecycle. The developed ontology is the first effort to define a semantic model for dynamic sensors, including datamatrix and QR codes. The evaluation of decoding and readability of identifiers (QR codes) showed good performance for detection of sensor state printed over and outside the QR code data matrix, i.e., the recognition ability with image vision algorithm was possible. The evaluation of the decoding performance of the QR code data matrix printed with sensors was also efficient, i.e., the QR code ability to be decoded with the reader after reversible and irreversible process of ink (dis)appearing was preserved, with slight drop in performance if ink density is low.

Experimental Characterization of Inkjet-Printed Stretchable Circuits for Wearable Sensor Applications

This paper introduces a cost-effective method for the fabrication of stretchable circuits on polydimethylsiloxane (PDMS) using inkjet printing of silver nanoparticle ink. The fabrication method, presented here, allows for the development of fully stretchable and wearable sensors. Inkjet-printed sinusoidal and horseshoe patterns are experimentally characterized in terms of the effect of their geometry on stretchability, while maintaining adequate electrical conductivity. The optimal fabricated circuit, with a horseshoe pattern at an angle of 45°, is capable of undergoing an axial stretch up to a strain of 25% with a resistance under 800 Ω. The conductivity of the circuit is fully reversible once it is returned to its pre-stretching state. The circuit could also undergo up to 3000 stretching cycles without exhibiting a significant change in its conductivity. In addition, the successful development of a novel inkjet-printed fully stretchable and wearable version of the conventional pulse oximeter is demonstrated. Finally, the resulting sensor is evaluated in comparison to its commercially available counterpart.

Flexible Blade-Coated Multicolor Polymer Light-Emitting Diodes for Optoelectronic Sensors

A method to print two materials of different functionality during the same printing step is presented. In printed electronics, devices are built layer by layer and conventionally only one type of material is deposited in one pass. Here, the challenges involving printing of two emissive materials to form polymer light-emitting diodes (PLEDs) that emit light of different wavelengths without any significant changes in the device characteristics are described. The surface-energy-patterning technique is utilized to print materials in regions of interest. This technique proves beneficial in reducing the amount of ink used during blade coating and improving the reproducibility of printed films. A variety of colors (green, red, and near-infrared) are demonstrated and characterized. This is the first known attempt to print multiple materials by blade coating. These devices are further used in conjunction with a commercially available photodiode to perform blood oxygenation measurements on the wrist, where common accessories are worn. Prior to actual application, the threshold conditions for each color are discussed, in order to acquire a stable and reproducible photoplethysmogram (PPG) signal. Finally, based on the conditions, PPG and oxygenation measurements are successfully performed on the wrist with green and red PLEDs.

Fully printed flexible fingerprint-like three-axis tactile and slip force and temperature sensors for artificial skin

A three-axis tactile force sensor that determines the touch and slip/friction force may advance artificial skin and robotic applications by fully imitating human skin. The ability to detect slip/friction and tactile forces simultaneously allows unknown objects to be held in robotic applications. However, the functionalities of flexible devices have been limited to a tactile force in one direction due to difficulties fabricating devices on flexible substrates. Here we demonstrate a fully printed fingerprint-like three-axis tactile force and temperature sensor for artificial skin applications. To achieve economic macroscale devices, these sensors are fabricated and integrated using only printing methods. Strain engineering enables the strain distribution to be detected upon applying a slip/friction force. By reading the strain difference at four integrated force sensors for a pixel, both the tactile and slip/friction forces can be analyzed simultaneously. As a proof of concept, the high sensitivity and selectivity for both force and temperature are demonstrated using a 3×3 array artificial skin that senses tactile, slip/friction, and temperature. Multifunctional sensing components for a flexible device are important advances for both practical applications and basic research in flexible electronics.