Ultrasensitive Strain Sensor Based on Separation of Overlapped Carbon Nanotubes

Although there have been remarkable improvements in stretchable strain sensors, the development of strain sensors with scalable fabrication techniques and which both high sensitivity and stretchability simultaneously is still challenging. In this work, a stretchable strain sensor based on overlapped carbon nanotube (CNT) bundles coupled with a silicone elastomer is presented. The strain sensor with overlapped CNTs is prepared by synthesizing line‐patterned vertically aligned CNT bundles and rolling and transferring them to the silicone elastomer. With the sliding and disconnection of the overlapped CNTs, the strain sensor performs excellently with a broad sensing range (≥145% strain), ultrahigh sensitivity (gauge factor of 42 300 at a strain of 125–145%), high repeatability, and durability. The performance of the sensor is also tunable by controlling the overlapped area of CNT bundles. Detailed mechanisms of the sensor and its applications in human motion detection are also further investigated. With the novel structure and mechanism, the sensor can detect a wide range of strains with high sensitivity, demonstrating the potential for numerous applications including wearable healthcare devices.     

A Solution‐Processable,Omnidirectionally Stretchable,and High‐Pressure‐Sensitive Piezoresistive Device

The development of omnidirectionally stretchable pressure sensors with high performance without stretching‐induced interference has been hampered by many challenges. Herein, an omnidirectionally stretchable piezoresistive pressure‐sensing device is demonstrated by combining an omniaxially stretchable substrate with a 3D micropattern array and solution‐printing of electrode and piezoresistive materials. A unique substrate structural design and materials mean that devices that are highly sensitive are rendered, with a stable out‐of‐plane pressure response to both static (sensitivity of 0.5 kPa^?1 and limit of detection of 28 Pa) and dynamic pressures and the minimized in‐plane stretching responsiveness (a small strain gauge factor of 0.17), achieved through efficient strain absorption of the electrode and sensing materials. The device can detect human‐body tremors, as well as measure the relative elastic properties of human skin. The omnidirectionally stretchable pressure sensor with a high pressure sensitivity and minimal stretch‐responsiveness yields great potential to skin‐attachable wearable electronics, human–machine interfaces, and soft robotics applications.     

Mechanocombinatorially Screening Sensitivity of Stretchable Strain Sensors

Stretchable strain sensors have aroused great interest for their application in human activity recognition, health monitoring, and soft robotics. For various scenarios involving the application of different strain ranges, specific sensitivities need to be developed, due to a trade‐off between sensor sensitivity and stretchability. Traditional stretchable strain sensors are developed based on conductive sensing materials and still lack the function of customizable sensitivity. A novel strategy of mechanocombinatorics is proposed to screen the sensor sensitivity based on mechanically heterogeneous substrates. Strain redistribution over substrates is optimized by mechanics and structure parameters, which gives rise to customizable sensitivity. As a proof of concept, a local illumination method is used to fabricate heterogeneous substrates with customizable mechanics and structure parameters. A library of mechanocombinatorial strain sensors is created for extracting the specific sensitivity. Thus, not only is an effective strategy for screening of sensor sensitivity demonstrated, but a contribution to the mechanocombinatorial strategy for personalized stretchable electronics is also made.     

Stretchable Electronic Sensors of Nanocomposite Network Films for Ultrasensitive Chemical Vapor Sensing

A stretchable, transparent, and body‐attachable chemical sensor is assembled from the stretchable nanocomposite network film for ultrasensitive chemical vapor sensing. The stretchable nanocomposite network film is fabricated by in situ preparation of polyaniline/MoS₂ (PANI/MoS₂) nanocomposite in MoS₂ suspension and simultaneously nanocomposite deposition onto prestrain elastomeric polydimethylsiloxane substrate. The assembled stretchable electronic sensor demonstrates ultrasensitive sensing performance as low as 50 ppb, robust sensing stability, and reliable stretchability for high‐performance chemical vapor sensing. The ultrasensitive sensing performance of the stretchable electronic sensors could be ascribed to the synergistic sensing advantages of MoS₂ and PANI, higher specific surface area, the reliable sensing channels of interconnected network, and the effectively exposed sensing materials. It is expected to hold great promise for assembling various flexible stretchable chemical vapor sensors with ultrasensitive sensing performance, superior sensing stability, reliable stretchability, and robust portability to be potentially integrated into wearable electronics for real‐time monitoring of environment safety and human healthcare.     

Auxetic Mechanical Metamaterials to Enhance Sensitivity of Stretchable Strain Sensors

Stretchable strain sensors play a pivotal role in wearable devices, soft robotics, and Internet‐of‐Things, yet these viable applications, which require subtle strain detection under various strain, are often limited by low sensitivity. This inadequate sensitivity stems from the Poisson effect in conventional strain sensors, where stretched elastomer substrates expand in the longitudinal direction but compress transversely. In stretchable strain sensors, expansion separates the active materials and contributes to the sensitivity, while Poisson compression squeezes active materials together, and thus intrinsically limits the sensitivity. Alternatively, auxetic mechanical metamaterials undergo 2D expansion in both directions, due to their negative structural Poisson's ratio. Herein, it is demonstrated that such auxetic metamaterials can be incorporated into stretchable strain sensors to significantly enhance the sensitivity. Compared to conventional sensors, the sensitivity is greatly elevated with a 24‐fold improvement. This sensitivity enhancement is due to the synergistic effect of reduced structural Poisson's ratio and strain concentration. Furthermore, microcracks are elongated as an underlying mechanism, verified by both experiments and numerical simulations. This strategy of employing auxetic metamaterials can be further applied to other stretchable strain sensors with different constituent materials. Moreover, it paves the way for utilizing mechanical metamaterials into a broader library of stretchable electronics.     

Transparent,stretchable, and rapid-response humidity sensor for body-attachable wearable electronics

Stretchable and conformal humidity sensors that can be attached to the human body for continuously monitoring the humidity of the environment around the human body or the moisture level of the human skin can play an important role in electronic skin and personal healthcare applications.However,most stretchable humidity sensors are based on the geometric engineering of non-stretchable components and only a few detailed studies are available on stretchable humidity sensors under applied mechanical deformations.In this paper,we propose a transparent,stretchable humidity sensor with a simple fabrication process,having intrinsically stretchable components that provide high stretchability,sensitivity,and stability along with fast response and relaxation time.Composed of reduced graphene oxide-polyurethane composites and an elastomeric conductive electrode,this device exhibits impressive response and relaxation time as fast as 3.5 and 7 s,respectively.The responsivity and the response and relaxation time of the device in the presence of humidity remain almost unchanged under stretching up to a strain of 60％ and after 10,000 stretching cycles at a 40％ strain.Further,these stretchable humidity sensors can be easily and conformally attached to a finger for monitoring the humidity levels of the environment around the human body,wet objects,or human skin.     

Highly Sensitive and Stretchable Resistive Strain Sensors Based on Microstructured Metal Nanowire/Elastomer Composite Films

High sensitivity and high stretchability are two conflicting characteristics that are difficult to achieve simultaneously in elastic strain sensors. A highly sensitive and stretchable strain sensor comprising a microstructured metal nanowire (mNW)/elastomer composite film is presented. The surface structure is easily prepared by combining an mNW coating and soft‐lithographic replication processes in a simple and reproducible manner. The densely packed microprism‐array architecture of the composite film leads to a large morphological change in the mNW percolation network by efficiently concentrating the strain in the valley regions upon stretching. Meanwhile, the percolation network comprising mNWs with a high aspect ratio is stable enough to prevent electrical failure, even under high strains. This enables the sensor to simultaneously satisfy high sensitivity (gauge factor ≈81 at >130% strain) and high stretchability (150%) while ensuring long‐term reliability (10 000 cycles at 150% strain). The sensor can also detect strain induced by bending and pressure, thus demonstrating its potential as a versatile sensing tool. The sensor is successfully utilized to monitor a wide range of human motions in real time. Furthermore, the unique sensing mechanism is easily extended to detect more complex multiaxial strains by optimizing the surface morphology of the device.     

3D‐Structured Stretchable Strain Sensors for Out‐of‐Plane Force Detection

Stretchable strain sensors, as the soft mechanical interface, provide the key mechanical information of the systems for healthcare monitoring, rehabilitation assistance, soft exoskeletal devices, and soft robotics. Stretchable strain sensors based on 2D flat film have been widely developed to monitor the in‐plane force applied within the plane where the sensor is placed. However, to comprehensively obtain the mechanical feedback, the capability to detect the out‐of‐plane force, caused by the interaction outside of the plane where the senor is located, is needed. Herein, a 3D‐structured stretchable strain sensor is reported to monitor the out‐of‐plane force by employing 3D printing in conjunction with out‐of‐plane capillary force‐assisted self‐pinning of carbon nanotubes. The 3D‐structured sensor possesses large stretchability, multistrain detection, and strain‐direction recognition by one single sensor. It is demonstrated that out‐of‐plane forces induced by the air/fluid flow are reliably monitored and intricate flow details are clearly recorded. The development opens up for the exploration of next‐generation 3D stretchable sensors for electronic skin and soft robotics.     

Monolayer Graphene Coupled to a Flexible Plasmonic Nanograting for Ultrasensitive Strain Monitoring

Plasmonically coupled graphene structures have shown great promise for sensing applications. Their complex and cumbersome fabrication, however, has prohibited their widespread application and limited their use to rigid, planar surfaces. Here, a plasmonic sensor based on gold nanowire arrays on an elastomer with an added graphene monolayer is introduced. The stretchable plasmonic nanostructures not only significantly enhance the Raman signal from graphene, but can also be used by themselves as a sensor platform for 2D strain sensing. These nanowire arrays on an elastomer are fabricated by template‐stripping based nanotransfer printing, which enables a simple and fast production of stable nanogratings. The ultrasmooth surfaces of such transferred structures facilitate reliable large‐area transfers of graphene monolayers. The resulting coupled graphene‐nanograting construct exhibits ultrahigh sensitivity to applied strain, which can be detected by shifts in the plasmonic‐enhanced Raman spectrum. Furthermore, this sensor enables the detection of adsorbed molecules on nonplanar surfaces through graphene‐assisted surface enhanced Raman spectroscopy (SERS). The simple fabrication of the plasmonic nanowire array platform and the graphene‐coupled devices have the potential to trigger widespread SERS applications and open up new opportunities for high‐sensitivity strain sensing applications.     

Hierarchical Synergistic Structure for High Resolution Strain Sensor with Wide Working Range

Strain sensors have been attracting tremendous attention for the promising application of wearable devices in recent years. However, the trade-off between high resolution, high sensitivity, and broad detection range is a great challenge for the application of strain sensors. Herein, a novel design of hierarchical synergistic structure (HSS) of Au micro cracks and carbon black (CB) nanoparticles is reported to overcome this challenge. The strain sensor based on the designed HSS exhibit high sensitivity (GF > 2400), high strain resolution (0.2%) even under large loading strain, broad detection range (>40%), outstanding stability (>12000 cycles), and fast response speed simultaneously. Further, the experiments and simulation results demonstrate that the carbon black layer greatly changed the morphology of Au micro-cracks, forming a hierarchical structure of micro-scale Au cracks and nano-scale carbon black particles, thus enabling synergistic effect and the double conductive network of Au micro-cracks and CB nanoparticles. Based on the excellent performance, the sensor is successfully applied to monitoring tiny signals of the carotid pulse during body movement, which illustrates the great potential in the application of health monitoring, human-machine interface, human motion detection, and electronic skin.     

Highly Morphology‐Controllable and Highly Sensitive Capacitive Tactile Sensor Based on Epidermis‐Dermis‐Inspired Interlocked Asymmetric‐Nanocone Arrays for Detection of Tiny Pressure

The tactile sensor lies at the heart of electronic skin and is of great importance in the development of flexible electronic devices. To date, it still remains a critical challenge to develop a large‐scale capacitive tactile sensor with high sensitivity and controllable morphology in an economical way. Inspired by the interlocked microridges between the epidermis and dermis, herein, a highly sensitive capacitive tactile sensor by creating interlocked asymmetric‐nanocones in poly(vinylidenefluoride‐co‐trifluoroethylene) film is proposed. Particularly, a facile method based on cone‐shaped nanoporous anodized aluminum oxide templates is proposed to cost‐effectively fabricate the highly ordered nanocones in a controllable manner and on a large scale. Finite‐element analysis reveals that under vertical forces, the strain/stress can be highly strengthened and localized at the contact apexes, resulting in an amplified variation of film permittivity and thickness. Benefiting from this, the developed tactile sensor presents several conspicuous features, including the maximum sensitivity (6.583 kPa^?1) in the low pressure region (0–100 Pa), ultralow detection limit (≈3 Pa), rapid response/recovery time (48/36 ms), excellent stability and reproducibility (10 000 cycles). These salient merits enable the sensor to be successfully applied in a variety of applications including sign language gesture detection, spatial pressure mapping, Braille recognition, and physiological signal monitoring.     

Flexible Hybrid Sensors for Health Monitoring: Materials and Mechanisms to Render Wearability

Wearable electronics have revolutionized the way physiological parameters are sensed, detected, and monitored. In recent years, advances in flexible and stretchable hybrid electronics have created emergent properties that enhance the compliance of devices to our skin. With their unobtrusive attributes, skin conformable sensors enable applications toward real-time disease diagnosis and continuous healthcare monitoring. Herein, critical perspectives of flexible hybrid electronics toward the future of digital health monitoring are provided, emphasizing its role in physiological sensing. In particular, the strategies within the sensor composition to render flexibility and stretchability while maintaining excellent sensing performance are considered. Next, novel approaches to the functionalization of the sensor for physical or biochemical stimuli are extensively covered. Subsequently, wearable sensors measuring physical parameters such as strain, pressure, temperature, as well as biological changes in metabolites and electrolytes are reported. Finally, their implications toward early disease detection and monitoring are discussed, concluding with a future perspective into the challenges and opportunities in emerging wearable sensor designs for the next few years.     

Metal Deposition on a Self‐Generated Microfibril Network to Fabricate Stretchable Tactile Sensors Providing Analog Position Information

Stretchable conductors and sensors have attracted great attention for use in electronic skin and healthcare monitoring. Despite the development of many stretchable conductors, there are still very few studies that utilize the conventional methods making electrodes and circuits used in current industry. A method is proposed to fabricate a stretchable electrode pattern and a stretchable tactile sensor by simply depositing linear metal lines through a mask on a stretchable substrate. A method is developed of a self‐generating microfibril network on the surface of stretchable block copolymer substrates. The formation mechanism of the microfibril network is studied with finite element method simulations. Metals (Au and Ag nanowires) are deposited directly on the substrate through a patterned mask. This study shows that strain‐insensitive circuit and strain‐sensitive sensor can be fabricated in a controlled way by adjusting the thickness of the deposited metal, which makes it easy to fabricate a tactile sensor by metal deposition. Also, by using the characteristic that the sensor has different sensitivity depending on the line pattern width, a novel sensor structure simultaneously providing analog‐type position information and pressure value is proposed.     

Surface Strain Redistribution on Structured Microfibers to Enhance Sensitivity of Fiber‐Shaped Stretchable Strain Sensors

Fiber‐shaped stretchable strain sensors with small testing areas can be directly woven into textiles. This paves the way for the design of integrated wearable devices capable of obtaining real‐time mechanical feedback for various applications. However, for a simple fiber that undergoes uniform strain distribution during deformation, it is still a big challenge to obtain high sensitivity. Herein, a new strategy, surface strain redistribution, is reported to significantly enhance the sensitivity of fiber‐shaped stretchable strain sensors. A new method of transient thermal curing is used to achieve the large‐scale fabrication of modified elastic microfibers with intrinsic microbeads. The proposed strategy is independent of the active materials utilized and can be universally applied for various active materials. The strategy used here will shift the vision of the sensitivity enhancement method from the active materials design to the mechanical design of the elastic substrate, and the proposed strategy can also be applied to nonfiber‐shaped stretchable strain sensors.     

Customization of Conductive Elastomer Based on PVA/PEI for Stretchable Sensors

Conductive, stretchable, environmentally‐friendly, and strain‐sensitive elastomers are attracting immense research interest because of their potential applications in various areas, such as human–machine interfaces, healthcare monitoring, and soft robots. Herein, a binary networked elastomer is reported based on a composite hydrogel of polyvinyl alcohol (PVA) and polyethyleneimine (PEI), which is demonstrated to be ultrastretchable, mechanically robust, biosafe, and antibacterial. The mechanical stretchability and toughness of the hydrogels are optimized by tuning the constituent ratio and water content. The optimal hydrogel (PVA₂PEI₁‐75) displays an impressive tensile strain as high as 500% with a corresponding tensile stress of 0.6 MPa. Furthermore, the hydrogel elastomer is utilized to fabricate piezoresistive sensors. The as‐made strain sensor displays seductive capability to monitor and distinguish multifarious human motions with high accuracy and sensitivity, like facial expressions and vocal signals. Therefore, the elastomer reported in this study holds great potential for sensing applications in the era of the Internet of Things (IoTs).     

Nanomaterial-Enabled Flexible and Stretchable Sensing Systems: Processing,Integration, and Applications

Nanomaterial-enabled flexible and stretchable electronics have seen tremendous progress in recent years, evolving from single sensors to integrated sensing systems. Compared with nanomaterial-enabled sensors with a single function, integration of multiple sensors is conducive to comprehensive monitoring of personal health and environment, intelligent human–machine interfaces, and realistic imitation of human skin in robotics and prosthetics. Integration of sensors with other functional components promotes real-world applications of the sensing systems. Here, an overview of the design and integration strategies and manufacturing techniques for such sensing systems is given. Then, representative nanomaterial-enabled flexible and stretchable sensing systems are presented. Following that, representative applications in personal health, fitness tracking, electronic skins, artificial nervous systems, and human–machine interactions are provided. To conclude, perspectives on the challenges and opportunities in this burgeoning field are considered.     

Mechanics for stretchable sensors

In the past decade, high performance stretchable sensors have found many exciting applications including epidermal and in vivo monitors, minimally invasive surgical tools, as well as deployable structure health monitors (SHM). Although wafer based electronics are known to be rigid and planar, recent advances in manufacture and mechanics have made intrinsically stiff and brittle inorganic electronic materials stretchable and compliant. This review article summarizes the most recent mechanics studies on stretchable sensors composed of ceramic and metallic functional materials. The discussion will focus around the most popular “island plus serpentine” design where active electronic or sensing components are housed on an array of isolated, micro-scale islands which are interconnected by electrically conductive, stretchable, serpentine thin films. The mechanics of polymer supported islands, freestanding serpentines, and polymer supported serpentines will be introduced. The effects of feature geometry and polymer substrate on the stretchability, compliance, as well as functionality of the sensor system will be discussed in details. The tradeoff between mechanics and functionality gives rise to the challenge of simultaneously optimizing the structure and performance of stretchable sensors.     

Bath Electrospinning of Continuous and Scalable Multifunctional MXene‐Infiltrated Nanoyarns

Electroactive yarns that are stretchable are desired for many electronic textile applications, including energy storage, soft robotics, and sensing. However, using current methods to produce these yarns, achieving high loadings of electroactive materials and simultaneously demonstrating stretchability is a critical challenge. Here, a one‐step bath electrospinning technique is developed to effectively capture Ti₃C₂T_x MXene flakes throughout continuous nylon and polyurethane (PU) nanofiber yarns (nanoyarns). With up to ≈90 wt% MXene loading, the resulting MXene/nylon nanoyarns demonstrate high electrical conductivity (up to 1195 S cm^?1). By varying the flake size and MXene concentration, nanoyarns achieve stretchability of up to 43% (MXene/nylon) and 263% (MXene/PU). MXene/nylon nanoyarn electrodes offer high specific capacitance in saturated LiClO₄ electrolyte (440 F cm^?3 at 5 mV s^?1), with a wide voltage window of 1.25 V and high rate capability (72% between 5 and 500 mV s^?1). As strain sensors, MXene/PU yarns demonstrate a wide sensing range (60% under cyclic stretching), high sensitivity (gauge factor of ≈17 in the range of 20–50% strain), and low drift. Utilizing the stretchability of polymer nanofibers and the electrical and electrochemical properties of MXene, MXene‐based nanoyarns demonstrate potential in a wide range of applications, including stretchable electronics and body movement monitoring.     

Flexible strain sensors fabricated using carbon-based nanomaterials: A review

Flexible strain sensors have experienced growing demand due to their several potential applications, such as personalized health monitoring, human motion detection, structural health monitoring, smart garments, and robots. Recently, several academic results have been reported concerning flexible and stretchable strain sensors. These reports indicate that the materials and design methods have an important influence on the performance of strain sensors. Carbon-based nanomaterials including carbon-based nanofibers, carbon nanotubes, graphene, and carbon black nanoparticles play a key role in the fabrication of flexible strain sensors with excellent properties. In terms of design, carbon-based nanomaterials are generally combined with polymers to maintain the flexibility and stability of a strain sensor. Various combined methods were successfully developed using different assembly structures of carbon-based nanomaterials in polymers, such as uniform mixing and ordered structures, including films, fibers, nanofiber membranes, yarns, foams, and fabrics. The working mechanisms of the flexible strain sensors, including changing the conductive network between overlapped nanomaterials, tunneling effect, and crack propagation, are also different compared with that of traditional semiconductor and metal sensors. The effects of the carbon-based nanomaterial structures in polymers on the strain sensing performance have been comprehensively studied and analyzed. The potential applications of flexible strain sensors and current challenges have been summarized and evaluated. This review provides some suggestions for further development of flexible and stretchable strain sensors with outstanding performance.     

全印制柔性应变传感器的原理与智能包装应用

目的随着可穿戴电子技术的快速发展,因具有较高的传感系数,柔性应变传感器在电子皮肤和机器人领域得到了广泛关注,但如何降低其制造成本成为一种挑战。近年来,印刷电子技术的快速发展推动了柔性应变传感器的发展,并逐渐在一些新的领域得到应用,尤其是智能包装领域。方法结合课题组在全印制应变传感器方面的研究进展,对柔性传感器的原理、印刷制造方法和主要应用进行综述。结论大量的研究表明,印刷柔性应变传感器已经开始应用于智能包装中,利用印刷电子技术制造智能包装也有利于降低其制造成本,推动其走向实际应用。