Synergistic Optimization toward the Sensitivity and Linearity of Flexible Pressure Sensor via Double Conductive Layer and Porous Microdome Array

Recently, wearable pressure sensors have attracted considerable interest in various fields such as healthcare monitoring, intelligent robots, etc. Although artificial structures or conductive materials have been well developed, the trade-off between sensitivity and linearity of pressure sensors is yet to be fully resolved by a traditional approach. Herein, from theoretical analysis to experimental design, we present the novel CPDMS/AgNWs double conductive layer (DCL) to synergistically optimize the sensitivity and linearity of piezoresistive pressure sensors. The facilely fabricated solid microdome array (SDA) is first employed as the elastomer to clarify the unrevealed working mechanism of DCL. Attributed to the synergistic effect of DCL, the DCL/SDA based sensor exhibits ultrahigh sensitivity (up to 3788.29 kPa-1) in an obviously broadened linearity range (0-6 kPa). We also demonstrated that the synergistic effect of DCL can be regulated with use of porous microdome array (PDA) to further optimize the sensing property. The linearity range can be improved up to 70 kPa while preserving the high sensitivity of 924.37 kPa-1 based on the interlocked PDA structure (IPDA), which is rarely reported in previous studies. The optimized sensitivity and linearity allow the competitive DCL/IPDA based sensor as a reliable platform to monitor kinds of physiological signals covering from low pressures (e.g., artery pulses), medium pressures (e.g., muscle expansions), to high pressures (e.g., body motions). We believe that the methodology along with the robust sensor can be of great potential for reliable healthcare monitoring and wearable electronic applications in the future.