A versatile surface micro structure design strategy for porous-based pressure sensors to enhance electromechanical performance

Abstract

Pressure sensors based on porous structures offer comfortable user experiences and can adapt to the flexible movement of human limbs, which makes them attractive options for human–computer interaction and health monitoring. However, ascribed to the limitation of porous surfaces, foam-based pressure sensors are difficult to achieve accurate electric responses and stable signal output, limiting their great potential in wide application fields. Herein, a surface structure design strategy is proposed for improving the performance of porous foam-based pressure sensors. The coupling of microstructures and the collaboration of dual sensing mechanisms endow the sensor with high performance, achieving a ∼ 12 times signal fluctuation stability when compared to the sensor without any surface design. Even when working under complex vibration conditions, the developed sensor can also maintain a ∼ 7 times more stable output. An intelligent insole based on the algorithm model of a sensor array and multi-layer perceptron was developed for the diagnosis of human foot arch health. The sensors with surface structure could capture and differentiate signals more accurately, which results in a diagnostic accuracy of 99.75 % for the smart insole. The strategy for enhancement of sensor performance proposed in this work can be applied to foam sensors with multiple material systems, which is expected to broaden the potential application of porous flexible devices in fields like the Internet of Things, medical monitoring and brain-computer interface.