Fabrication of Fabric-based Piezoresistive Sensors Based on Chemically Deposited Fabric Silver Electrodes and PDMS-MWCNTs/CB Composite Films with Thermally Expandable Microspheres

Optimizing the fabrication process of fabric electrodes and creating active layers with a controlled pore structure is crucial for advancing high-performance flexible pressure sensors. This work proposes an approach to manufacturing fabric-based piezoresistive sensors. Specifically, it utilizes the liquid-phase chemical reduction method with microdroplet jetting technology and the thermally expandable microsphere foaming method. The impact of conductive material filling content and the microsphere expansion process on the active layer performance was investigated. Additionally, the electrical properties of fabric metal silver electrodes were evaluated, along with the sensing capabilities and applications of the sensors. The results reveal that the electrodes exhibit an average sheet resistance of 0.023 Ω sq-1. The sensor displays a sensitivity of 0.21 kPa-1, with a response-recovery time of approximately 300/200 ms and repeatability over 5000 s. Human motion signal tests of the sensor demonstrate its potential in healthcare and sports monitoring applications.