Breaking the Saturation of Sensitivity for Ultrawide Range Flexible Pressure Sensors by Soft-Strain Effect.

The flexible pressure sensors with a broad pressure range and unsaturated sensitivity are highly desired in practical applications. However, pressure sensors by piezoresistive effect are always limited by the compressibility of sensing layers, resulting in a theoretically decreasing sensitivity of less than 100%. Here, a unique strategy is proposed that utilizes the strain effect, simultaneously achieving a trade-off between a wider pressure detection range and unsaturated sensitivity. Ascribed to the strain effect of sensing layers induced by interlaced microdomes, the sensors possess an increased sensitivity (5.22-70 MPa-1) over an ultrawide pressure range (45 Pa-4.1 MPa), a high-pressure resolution (5 Pa), fast response/recovery time (30/45 ms), and a robust response under a high-pressure loading of 3.5 MPa for more than 5000 cycles. These superior sensing performances allow the sensor to monitor large pressure. The flexible pressure sensor array can assist doctors in restoring the neutral mechanical axis, tracking knee flexion angles, and extracting gait features. Moreover, the flexible sensing array can be integrated into the joint motion surveillance system to map the balance medial-lateral contact forces on the metal compartments in real time, demonstrating the potential for further development into precise medical human-machine interfaces during total knee replacement surgery.

Scalable Manufacturing of Large-Area Pressure Sensor Array for Sitting Posture Recognition in Real Time.

Pressure sensors are considered the key technology for potential applications in real-time health monitoring, artificial electronic skins, and human-machine interfaces. Despite the significant progress in developing novel sensitive materials and constructing unique sensor structures, it remains challenging to fabricate large-area pressure sensor arrays due to the involvement of complex procedures including photolithography, laser writing, or coating. Herein, a scalable manufacturing approach for the realization of pressure sensor arrays with substantially enlarged sensitive areas is proposed using a versatile screen-printing technique. A compensation mechanism is introduced into the printing process to ensure the precise alignment of conductive electrodes, insulation layers, and sensitive microstructures with an alignment error of less than 4 µm. The fully screen-printed sensors exhibit excellent collective sensing performance, such as a reasonable pressure sensitivity of -2.2 kPa-1, a fast response time of 40 ms, and superior durability over 3000 consecutive pressures. Additionally, an integrated 16 × 32 pressure sensor array with a sensing area of 190 × 380 mm2 is demonstrated to precisely recognize the sitting postures and the body weights, showing great potential in continuous and real-time health status monitoring.

Large-Scale Ultra-Robust MoS2 Patterns Directly Synthesized on Polymer Substrate for Flexible Sensing Electronics.

Synthesis of large-area patterned MoS2 is considered the principle base for realizing high-performance MoS2 -based flexible electronic devices. Patterning and transferring MoS2 films to target flexible substrates, however, require conventional multi-step photolithography patterning and transferring process, despite tremendous progress in the facilitation of practical applications. Herein, an approach to directly synthesize large-scale MoS2 patterns that combines inkjet printing and thermal annealing is reported. An optimal precursor ink is prepared that can deposit arbitrary patterns on polyimide films. By introducing a gas atmosphere of argon/hydrogen (Ar/H2 ), thermal treatment at 350 °C enables an in situ decomposition and crystallization in the patterned precursors and, consequently, results in the formation of MoS2 . Without complicated processes, patterned MoS2 is obtained directly on polymer substrate, exhibiting superior mechanical flexibility and durability (≈2% variation in resistance over 10,000 bending cycles), as well as excellent chemical stability, which is attributed to the generated continuous and thin microstructures, as well as their strong adhesion with the substrate. As a step further, this approach is employed to manufacture various flexible sensing devices that are insensitive to body motions and moisture, including temperature sensors and biopotential sensing systems for real-time, continuously monitoring skin temperature, electrocardiography, and electromyography signals.