High-performance Strain Sensors Research Articles

High-Performance Flexible Strain Sensor Based on Thermoplastic Polyurethane Melt-Blown Nonwoven with Molybdenum Disulfide for Human Motion Monitoring

High-Performance Flexible Strain Sensor Based on Thermoplastic Polyurethane Melt-Blown Nonwoven with Molybdenum Disulfide for Human Motion Monitoring

High-Performance Stretchable Strain Sensors Based on Auxetic Fabrics for Human Motion Detection.

Wearable strain sensors play a pivotal role in real-time human motion detection and health monitoring. Traditional fabric-based strain sensors, typically with a positive Poisson's ratio, face challenges in maintaining sensitivity and comfort during human motion due to conflicting resistance changes in different strain directions. In this work, high-performance stretchable strain sensors are developed based on graphene-modified auxetic fabrics (GMAF) for human motion detection in smart wearable devices. The proposed GMAF sensors, with a negative Poisson's ratio achieved through commercially available warp-knitting technology, exhibit an 8-fold improvement in sensitivity compared to conventional plain fabric sensors. The unique auxetic fabric structure enhances sensitivity by synchronizing resistance changes in both wale and course directions. The GMAF sensors demonstrate excellent washability, showing only slight degradation in auxeticity and an acceptable increase in resistance after 10 standard wash cycles. The GMAF sensors maintain stability under different strain levels and various motion frequencies, emphasizing their dynamic performance. The sensors exhibit superior conformability to joint movements, which effectively monitor a full range of motions, including joint bending, sports activities, and subtle actions like coughing and swallowing. The research underscores a promising approach to achieve industrial-scale production of wearable sensors with improved performance and comfort through fabric structure design.

Strong, tough and environment-tolerant organohydrogels for flaw-insensitive strain sensing.

Conductive organohydrogels are promising for strain sensing, while their weak mechanical properties, poor crack propagation resistance and unstable sensing signals during long-term use have seriously limited their applications as high-performance strain sensors. Here, we propose a facile method, i.e., solvent exchange assisted hot-pressing, to prepare strong yet tough, transparent and anti-fatigue ionically conductive organohydrogels (ICOHs). The densified polymeric network and improved crystallinity endow ICOHs with excellent mechanical properties. The tensile strength, toughness, fracture energy and fatigue threshold of ICOHs can reach 36.12 ± 4.15 MPa, 54.57 ± 2.89 MJ m-3, 43.44 ± 8.54 kJ m-2 and 1212.86 ± 57.20 J m-2, respectively, with a satisfactory fracture strain of 266 ± 33%. In addition, ICOH strain sensors with freezing and drying resistance exhibit excellent cycling stability (10 000 cycles). More importantly, the fatigue resistance allows the notched strain sensor to work normally with no crack propagation and output stable and reliable sensing signals. Overall, the unique flaw-insensitive strain sensing makes ICOHs promising in the field of wearable and durable electronics.

A highly responsive and sensitive flexible strain sensor with conductive cross-linked network by laser direct writing

As a critical component of wearable electronic devices, flexible strain sensors have made significant contributions in the fields of smart healthcare, motion monitoring and communication, garnering escalating research interests. However, the pursuit of ideal materials synergizing high sensitivity with facile and cost-effective manufacturing methodologies remains a persistent challenge, significantly hindering the full realization of the potential of flexible strain sensors. Herein, an innovative hybrid conductive network architecture constituted by multi-walled carbon nanotubes and laser-induced graphene (MWCNTs/LIG) has been explored via a facile, cost-effective, controllable, and environmentally friendly laser direct writing (LDW) technique. Subsequently, the resultant MWCNTs/LIG composite with a cross-linked microstructure has been harnessed for the fabrication of a high-performance strain sensor. Notably, the proposed sensor exhibits remarkable sensitivity with a gauge factor (GF) reaching 192, rapid response and recovery times of 27/20 ms, and favorable durability exceeding 2300 cycles. Furthermore, the developed sensor demonstrates the capability to accurately capture full-range motions in real-time, as well as the ability to transmit information as a portable communication device. This promising discovery offers a new insight for the flourishing development of high-performance flexible strain sensors in the realm of wearable sensing.

Ultrasensitive, highly stretchable and multifunctional strain sensors based on scorpion-leg-inspired gradient crack arrays

Wearable flexible strain sensors based on conductive films have shown great application potential in many high-tech fields. They have high requirements for synergistic performances of sensitivity, flexibility, stability and durability. However, overcoming the trade-off between high sensitivity and high stretchability is still a great challenge in this research. Here we develop a facile strategy to prepare high-performance flexible strain sensors based on gradient crack arrays inspired by the gradient slits on scorpion legs. The gradient crack arrays with branched or hierarchical features controllably form in a periodic thickness-gradient metal film prepared by one-step masking technique on a flexible substrate. The cracks are progressively open from the thickest film region to the thinnest one under mechanical strain, behaving a unique sensing mechanism. As a result, the gradient crack-based strain sensors possess excellent comprehensive performances including high sensitivity (up to 21000), wide sensing range (∼70 %), low detection limit (0.02 %), quick response speed (below to 80 ms), excellent stability and durability (up to 15,000 cycles at 5 % strain). As demonstration of applications, the sensors are used to monitor various human activities and to express and encrypt information by bending bidirectionally. This work provides a novel way to fabricate highly sensitive, stretchable, robust, multifunctional, crack-based flexible strain sensors, which would greatly expand the applications in flexible electronics and wearable devices.

Fabrication of PHFPO Surface-Modified Conductive AgNWs/PNAGA Hydrogels with Enhanced Water Retention Capacity toward Highly Sensitive Strain Sensors.

Conductive hydrogels, characterized by their unique features of flexibility, biocompatibility, electrical conductivity, and responsiveness to environmental stimuli, have emerged as promising materials for sensitive strain sensors. In this study, a facile strategy to prepare highly conductive hydrogels is reported. Through rational structural and synthetic design, silver nanowires (AgNWs) are incorporated into poly(N-acryloyl glycinamide) (PNAGA) hydrogels, achieving high electrical conductivity (up to 0.88 S m-1), significantly enhanced mechanical properties, and elevated deformative sensitivity. Furthermore, surface modification with polyhexafluoropropylene oxide (PHFPO) has substantially improved the water retention capacity and dressing comfort of this hydrogel material. Based on the above merits, these hydrogels are employed to fabricate highly sensitive wearable strain sensors which can detect and interpret subtle hand and finger movements and enable precise control of machine interfaces. The AgNWs/PNAGA based strain sensors can effectively sense finger motion, enabling the control of robotic fingers to replicate the human hand's gestures. In addition, the high deformative sensitivity and elevated water retention performance of the hydrogels makes them suitable for flow sensing. These conceptual applications demonstrate the potential of this conductive hydrogel in high-performance strain sensors in the future.

High-Performance Multidirectional Flexible Strain Sensor for Human Motion and Health Monitoring.

Multidirectional strain sensors are pivotal for wearable electronic devices and human-computer interaction. In this investigation, we translocate carbon/graphene (CB/Gr) conductive nanocomposites onto an Ecoflex flexible substrate via a facile technique encompassing reverse molding and spraying, culminating in the fabrication of a 45° strain rosette-shaped multidirectional flexible strain sensor. The sensor distinguishes itself with extraordinary performance characteristics, including high sensitivity (boasting a gauge factor of 35), an extensive strain range from 0 to 100%, exceptional linearity, a rapid response time of merely 200 ms, remarkable stability, and outstanding durability, effortlessly withstanding over 5000 stretch-release cycles. The sensor exhibits its exceptional capability to discern intricate movements, particularly in detecting human hand and neck motions. The sensor's remarkable comprehensive performance and strain direction recognition ability underscore its significant potential for diverse applications, notably in human-computer interaction, human motion monitoring, and health monitoring.

Sensitive strain sensors with wide-range detection and high stability for intelligent human motion monitoring

Miniaturized wearable electronic devices with strain sensors as core sensing elements hold significant applications in health monitoring and human-machine interaction. However, it remains a challenge to develop strain sensors with optimal response linearity, a wide detection range, and stability. In this study, to satisfy the above requirements, we construct high-performance wearable strain sensors (rGO-CNTOH@PSE) by a strategy of hybridizing conductive fillers with stretchable substrates. In detail, a synergistic conductive network is developed by adopting OH-containing carbon nanotube (CNTOH) and reduced graphene oxide (rGO) fillers with an appropriate mass ratio. After the network is integrated into a porous silicone elastomer substrate formed by the salt templating method, the developed strain sensor exhibits distinct resolution, consistent repeatability, and superior response linearity across a wide strain detection range of 0.3–303.03 %. Furthermore, the sensor also maintains good response stability over 15000 cycles of strain. We also demonstrate that this strain sensor showing outstanding exceptional detection performance has the capability for full-range human motion detection. A wireless smart electronic glove is developed based on the sensor, which can accurately recognize gesture movements and control a bionic robotic hand to replicate human hand actions, offering the potential for replacing manual tasks (such as, grasping in hazardous environments) in the future.

Construction of “island-bridge” microstructured conductive coating for enhanced impedance response of organohydrogel strain sensor

Flexible conductive hydrogels (CHs) have received widespread attention in the field of wearable strain sensor, electronic skin, and artificial intelligence owing to their excellent stretchability, biocompatibility, and real-time sensing performance. However, it still remains a critical challenge to design and construct the satisfactory wearable strain sensor integrated with high sensitivity, wide sensing range, and environmental stability, especially at extreme temperatures. Herein, ionic conductive polyacrylamide/sodium alginate nanocomposite organohydrogel anchored with electronic conductive “island-bridge” microstructured carbon nanotubes (CNTs) conformal coating was designed and fabricated for high-performance strain sensor, of which the existence of “island-bridge” microstructured electronic conductive layer and its special structure evolution upon external stretching can significantly enhance the alternating current impedance response behavior of the sensor, featuring with a high sensitivity of 76.54 at 600 % strain, wide sensing range (0–600 % strain), fast responsiveness (110 ms), extremely low detection limit (0.1 %), and favorable stability and reproducibility of over 3200 cycles. Meanwhile, the resultant organohydrogel strain sensor can precisely detect and differentiate complicated human activities even at the environment temperatures of −30 °C and 50 °C, opening a promising avenue for next-generation smart wearable electronics.

Design of flexible micro-porous fiber with double conductive network synergy for high-performance strain sensor

Flexible wearable strain sensor is a vital part of intelligent wearable systems due to their broad applications in human–machine interaction and smart clothes. Flexible strain sensor fabricated via conventional blending conductive polymer composites has some drawbacks, for example, low sensitivity, large hysteresis, and “shoulder-peak” phenomenon, which limit their practical applications greatly. Herein, we prepared a fiber-shaped strain sensor with a micro-porous, three-layer structure together with a dual conductive network based on reduced graphene oxide (rGO) and multi-walled carbon nanotubes (MWCNTs). The strain sensor demonstrates excellent response behaviors, including splendid stretchability (686 %), wide detection range (120 %), high sensitivity (gauge factor = 300), fast response time (300 ms) and excellent durability (over 9000 cycles). The unique dual conductive network structure endows the strain sensor with remarkable recoverability and reproducibility. The resistance of the strain sensor can recover to nearly initial conditions after the releasing process, exhibiting lower hysteresis. The “shoulder-peak” phenomenon has also been weakened based on the microstructure and conductive network design. Based on the high sensitivity and excellent response behavior, the fiber-shaped strain sensor performs real-time monitoring of breathing, finger bending, walking, and other human motions, providing a good candidate for its application in intelligent wearable devices.

Biodegradable poly(lactic acid) blocked polyurethane/carbon nanotubes coated cotton fabric prepared by ultrasonic-assisted inkjet printing for high performance strain sensors

In order to fulfill the demands for degradability, a broad working range, and heightened sensitivity in flexible sensors, biodegradable polyurethane (BTPU) was synthesized and combined with CNTs to produce BTPU/CNTs coated cotton fabric using an ultrasonic-assisted inkjet printing process. The synthesized BTPU displayed a capacity for degradation in a phosphate buffered saline solution, resulting in a weight loss of 25 % after 12 weeks of degradation. The BTPU/CNTs coated cotton fabric sensor achieved an extensive strain sensing range of 0–137.5 %, characterized by high linearity and a notable sensitivity (gauge factor (GF) of 126.8). Notably, it demonstrated a low strain detection limit (1 %), rapid response (within 280 ms), and robust durability, enabling precise monitoring of both large and subtle human body movements such as finger, wrist, neck, and knee bending, as well as swallowing. Moreover, the BTPU/CNTs coated cotton fabric exhibited favorable biocompatibility with human epidermis, enabling potential applications as wearable skin-contact sensors. This work provides insight into the development of degradable and high sensing performance sensors suitable for applications in electronic skins and health monitoring devices.

Tunable porous fiber-shaped strain sensor with synergistic conductive network for human motion recognition and tactile sensing

With the rapid development of portable electronic products, smart wearable devices show great application potential in personalized motion monitoring, health monitoring and even in human-machine interaction. In particular, high-performance flexible fiber-shaped strain sensors are receiving more and more attention because they can be well integrated with clothes or human skin for real-time human activities monitoring. However, achieving improved sensitivity, wide detection range, diverse applications and easy operation of them remains a challenge. Here, we adopt a simple wet-spinning technique to prepare a porous fiber-shaped carbon nanotubes (CNTs)/silver nanoparticles (AgNPs)/thermoplastic polyurethane (TPU) fiber (CATF) for high-performance strain sensor, of which the synergistic conductive network of CNTs and AgNPs enables a wide detection range (∼248 %), high sensitivity (GF > 4295), fast response/recovery time (120 ms/140 ms) and excellent stability. Interestingly, strain sensing range and sensitivity of the sensor can be tuned by changing the AgNPs loading to make it suitable for different application scenarios. All the merits of the sensor make it capable for diverse human movements monitoring, pronunciation recognition, and gesture recognition. More importantly, our prepared CATF strain sensor can be easily weaved into wearable smart textiles, showing great potential for tactile sensing to realize multi-touch and pressure tracking. Finally, the CATF also displays efficient photothermal conversion capability even under different tensile strains up to 150 %, showing great potential in human body thermal management to improve the wearing comfort of wearable electronic fabric.

Nature-inspired wood-like TPU/CB aerogels for high performance flexible strain sensors

Strain sensors based on porous conductive polymers (CPCs) have garnered growing research interest for their potential applications in motion detection, healthcare, human–computer interaction, and artificial intelligence. However, the complexity of CPC processing makes it difficult to achieve the controlled design of microscopic porous structures, leading to simple and random porous structures, thus limiting their further use in the field of pressure sensing. This paper presents a strain sensor with a high-performance, wood-like structure composed of flexible conductive carbon black/plastic polyurethane foam (BWCT) using a bidirectional freeze casting process. The results show that, compared with conventional random freezing and unidirectional freezing, the bidirectional freeze casting process can effectively realize multiscale control of the composite structure, which results in a good laminar porous structure of the prepared BWCT. This parallel laminar structure not only contributes to the layered transfer of stresses but also avoids the local concentration of stresses. At the same time, it significantly increases the directional electrical conduction ability, which results in high sensing stability performance. In particular, the BWCT sensors had a wide detection range (80%), a lower limit of detection (0.2%), rapid response and relaxation times (200 ms), as well as exceptional durability (>2000 cycles). Furthermore, the BWCT was integrated into a wearable sensor to monitor various human motions, including arm bending, squatting, and walking, demonstrating reliable detection performance. Altogether, the BWCT sensors are promising in expanding the application but also offer guidance for designing high-performance wearable strain sensors.

In-situ forming ultra-mechanically sensitive materials for high-sensitivity stretchable fiber strain sensors.

Fiber electronics with flexible and weavable features can be easily integrated into textiles for wearable applications. However, due to small sizes and curved surfaces of fiber materials, it remains challenging to load robust active layers, thus hindering production of high-sensitivity fiber strain sensors. Herein, functional sensing materials are firmly anchored on the fiber surface in-situ through a hydrolytic condensation process. The anchoring sensing layer with robust interfacial adhesion is ultra-mechanically sensitive, which significantly improves the sensitivity of strain sensors due to the easy generation of microcracks during stretching. The resulting stretchable fiber sensors simultaneously possess an ultra-low strain detection limit of 0.05%, a high stretchability of 100%, and a high gauge factor of 433.6, giving 254-folds enhancement in sensitivity. Additionally, these fiber sensors are soft and lightweight, enabling them to be attached onto skin or woven into clothes for recording physiological signals, e.g. pulse wave velocity has been effectively obtained by them. As a demonstration, a fiber sensor-based wearable smart healthcare system is designed to monitor and transmit health status for timely intervention. This work presents an effective strategy for developing high-performance fiber strain sensors as well as other stretchable electronic devices.

Ultra-stretchable and anti-freezing ionic conductive hydrogels as high performance strain sensors and flexible triboelectric nanogenerator in extreme environments

Conductive hydrogels have shown promising applications in a variety of portable smart wearable electronics and flexible sensors due to their high flexibility, stretchability, adjustable mechanical properties and excellent electrical conductivity. However, most of the current hydrogel-based flexible strain sensors and portable triboelectric nanogenerator (TENG) generally suffer from low stretchability/flexibility, poor mechanical properties, weak low-temperature tolerance and low power output. Herein, a multifunctional ionic conductive hydrogel (PPAVC-BA) with ultra-stretchability (∼1750%), high transparency (85%), high electrical conductivity (13.7 mS/cm), and outstanding anti-freezing properties (below −80°C without freezing). The strain sensor assembled from the PPAVC-BA hydrogel shows high sensitivity (GF=4.43) and ultra-wide sensing detection range (0%-1100%) as well as fast response time. Based on these properties, the PPAVC-BA hydrogel strain sensor can accurately recognize different joint movements of the human body as well as weak muscle beats. In addition, the PPAVC-BA hydrogel-based TENG (PPAVC-BA-TENG) exhibits excellent electrical output performance, with an open circuit voltage (Voc) of about 420 V, a short circuit current (Isc) of 23 μA, a short-circuit transfer charge (Qsc) of 112 nC and a maximum power density of 2246.03 mW/m2, which allows it to power small electronic devices. This PPAVC-BA-TENG also shows outstanding tensile performance and can output stable electrical signals at 200% strain. Impressively, the PPAVC-BA-TENG exhibits good electrical output performance even at low temperature of −50°C and high temperature of 80°C. The flexible strain sensors and stretchable TENG for high performance and multifunctionality reported in this work provide viable references in the development of motion detection, energy harvesting and self-powered electronic devices.

A Highly Sensitive Strain Sensor with Wide Linear Sensing Range Prepared on a Hybrid-Structured CNT/Ecoflex Film via Local Regulation of Strain Distribution.

With the development of information technology, high-performance wearable strain sensors with high sensitivity and stretchability have played a significant role in motion detection. However, many high-sensitivity and outstanding-stretchability strain sensors possess a limited linear sensing range, which limits the enhancement of the flexible strain sensors' performance. Herein, we develop a hybrid-structured carbon nanotube (CNT)/Ecoflex strain sensor with laser-engraved grooves along with punched circular holes in a composite CNT/Ecoflex film by vacuum filtration and permeation. By optimizing the distribution of grooves and circular holes, the strain in the sensing layer can be locally regulated, which alters the morphology of cracks under strain and allows the hybrid-structured CNT/Ecoflex strain sensor to simultaneously exhibit high sensitivity (GF = 43.8) as well as a wide linear sensing range (200%). On the basis of excellent performance, the hybrid-structured CNT/Ecoflex strain sensor is capable of detecting movements in various parts of the human body, including movements of larynx and joint bending.

Wearable strain sensor utilizing the synergistic effect of Ti3C2Tx MXene/AgNW nanohybrid for point-of-care respiratory monitoring

Respiratory signals are significant indicators for detecting changes in physiological conditions and early diagnosis of numerous respiratory illnesses. Herein, we have integrated a high-performance strain sensor and portable circuit board (PCB) with personalized interface to develop point-of-care respiratory monitoring device. The ultrasensitive strain sensor utilizes a conductive polymeric nanocomposite that harnesses the synergistic effect of Ti3C2Tx (MXene)/AgNW nanohybrid to develop a wearable device. The wearable device is capable of analysing pulmonary volumes, such as forced volume capacity (FVC) and forced expiratory volume (FEV1), while accurately recognizing various breathing patterns in a resting state (such as normal, forced, and obstructive), as well as during different physical activities. It shows excellent correlation (>93%) with commercial spirometer for measurement of pulmonary parameters. In addition, we present a wireless device for lab rat respiratory monitoring in anaesthetic state. The device is implemented for real-time respiratory monitoring under mild, normal and high anaesthesia doses. The levels of anaesthesia doses including a critical limit can be significantly discriminated by means of breathing frequency and amplitude, which ultimately results in saving their lives. These results demonstrate the practical feasibility of the strain sensing device as wearable electronics for point-of-care respiratory monitoring in humans and other species.

Designable high-performance TPU foam strain sensors towards human-machine interfaces

Flexible, breathable, and stable sensors were important in developing human–computer interaction systems and novel wearable devices. However, major challenges were still faced in two aspects, 1) high-performance strain sensors with a large sensing range, and 2) an interaction mode that is both convenient and efficient. Herein, we developed a thermoplastic polyurethane large-skeleton foam (TPU-LS foam) through a steam-induced method. The strain sensor comprised three layers of breathable foam, with CNTs/rGO TPU-LS foam as the inner layer and pure foam as the protective layer. PDMS/TiO2 was sprayed to create a UV-resistant and self-repairing coating, achieving a 66% melanin inhibition rate and a 91% repair rate. The sensor presented a wide work range over 100%, a high gauge factor of 637.8, and long-term durability. We trained machine learning frameworks to recognize different gestures and designed two types of human–computer interaction applications, allowing users to operate apps with gestures.

Vertical graphene-decorated carbon nanofibers establishing robust conductive networks for fiber-based stretchable strain sensors

Stretchable strain sensors have great potential for diverse applications including human motion detection, soft robotics, and health monitoring. However, their practical implementation requires improved repeatability and stability along with high sensing performances. Here, we utilized spiky vertical graphene (VG) sheets decorated on carbon nanofibers (VG@CNFs) to establish reliable conductive networks for resistive strain sensing. Three-dimensional (3D) VG@CNFs combined with reduced graphene oxide (rGO) sheets were simply coated on stretchable spandex fibers by ultrasonication. Because of the spiky geometry of the VG sheets, VG@CNF and rGO exhibited enhanced interactions, which was confirmed by mode I fracture tests. Due to the robust conductive networks formed by the VG@CNF and rGO hybrid, the fiber strain sensor exhibited a significantly improved strain range of up to 522% (with a high gauge factor of 1358) and stable resistance changes with minimal variation even after 5000 stretching–releasing cycles under a strain of 50%. In addition, the textile strain sensor based on the VG@CNF/rGO hybrid showed even improved repeatability for various strain levels of 10% to 200%, enabling its implementation on leggings for monitoring of squat posture. This study demonstrates the high potential of the 3D VG@CNF for high-performance and reliable stretchable strain sensors.

Ultrasensitive and highly stretchable bilayer strain sensor based on bandage-assisted woven fabric with reduced graphene oxide and liquid metal

Flourishing flexible and wearable strain sensors still meet a challenge to realize ultrahigh sensitivity and wide working range simultaneously through a convenient strategy. Here, a strain sensor is designed based on natural rubber (NR) matrix and a bilayer structure composed of a highly stretchable liquid metal (LM) layer and a susceptible reduced graphene oxide (RGO)@carbonized bandage (CB) layer. By painting LM onto the surface of a graphene oxide (GO)-coated bandage template followed with a rapid flame pyrolysis, a dual conductive-layer woven fabric based on LM/RGO@CB was obtained. NR was then employed as an elastic substrate. Benefiting from the synergistic bilayer network and the high stretchability of the elastomer, the fabricated strain sensor exhibited ultrahigh sensitivity (gauge factor of up to 1.63 × 105), quite wide detection range (strain of 0 ∼ 515 %), low detection limit (0.25 %), fast response/recovery (135 ms/135 ms), and satisfactory durability (5700 cycles). The extraordinary strain-sensing performance allowed comprehensive monitoring of full-range (vigorous and subtle) human motions and physiological activities. This work provides a facile bilayer strategy for the preparation of high-performance strain sensors.