Soft printed electronics exhibit unique structures and flexibilities suited for a plethora of wearable applications. However, forming scalable, reliable multilayered electronic devices with heterogeneous material interfaces on soft substrates, especially on porous and anisotropic structures, is highly challenging. In this study, we demonstrate an all-inkjet-printed textile capacitor using a multilayered structure of bilayer polymer dielectrics and particle-free metal−organic decomposition (MOD) silver electrodes. Understanding the inherent porous/anisotropic microstructure of textiles and their surface energy relationship was an important process step for successful planarization. The MOD silver ink formed a foundational conductive layer through the uniform encapsulation of individual fibers without blocking fiber interstices. Urethane-acrylate and poly(4-vinylphenol)-based bilayers were able to form a planarized dielectric layer on polyethylene terephthalate textiles. A unique chemical interaction at the interfaces of bilayer dielectrics performed a significant role in insulating porous textile substrates resulting in high chemical and mechanical durability. In this work, we demonstrate how textiles' unique microstructures and bilayer dielectric layer designs benefit reliability and scalability in the inkjet process as well as the use in wearable electronics with electromechanical performance.
Pressure sensors for wearable healthcare devices, particularly force sensitive resistors (FSRs) are widely used to monitor physiological signals and human motions. However, current FSRs are not suitable for integration into wearable platforms. This work presents a novel technique for developing textile FSRs (TFSRs) using a combination of inkjet printing of metal-organic decomposition silver inks and heat pressing for facile integration into textiles. The insulating void by a thermoplastic polyurethane (TPU) membrane between the top and bottom textile electrodes creates an architectured piezoresistive structure. The structure functions as a simple logic switch where under a threshold pressure the electrodes make contact to create conductive paths (on-state) and without pressure return to the prior insulated condition (off-state). The TFSR can be controlled by arranging the number of layers and hole diameters of the TPU spacer to specify a wide range of activation pressures from 4.9 kPa to 7.1 MPa. For a use-case scenario in wearable healthcare technologies, the TFSR connected with a readout circuit and a mobile app shows highly stable signal acquisition from finger movement. According to the on/off state of the TFSR with LED bulbs by different weights, it can be utilized as a textile switch showing tactile feedback.
Next generation textile‐based wearable sensing systems will require flexibility and strength to maintain capabilities over a wide range of deformations. However, current material sets used for textile‐based skin contacting electrodes lack these key properties, which hinder applications such as electrophysiological sensing. In this work, a facile spray coating approach to integrate liquid metal nanoparticle systems into textile form factors for conformal, flexible, and robust electrodes is presented. The liquid metal system employs functionalized liquid metal nanoparticles that provide a simple “peel‐off to activate” means of imparting conductivity. The spray coating approach combined with the functionalized liquid metal system enables the creation of long‐term reusable textile‐integrated liquid metal electrodes (TILEs). Although the TILEs are dry electrodes by nature, they show equal skin‐electrode impedances and sensing capabilities with improved wearability compared to commercial wet electrodes. Biocompatibility of TILEs in an in vivo skin environment is demonstrated, while providing improved sensing performance compared to previously reported textile‐based dry electrodes. The “spray on dry—behave like wet” characteristics of TILEs opens opportunities for textile‐based wearable health monitoring, haptics, and augmented/virtual reality applications that require the use of flexible and conformable dry electrodes.
The low-temperature processing, inherent flexibility, and biocompatibility of piezoelectric polymers such as poly(vinylidene fluoride) (PVDF)-based materials enable the creation of soft wearable sensors, energy harvesters, and actuators. Of the various processing techniques, electrospinning is the most widely adopted process to form PVDF nanofiber scaffolds with enhanced piezoelectric properties such that they do not require further post-processing such as mechanical drawing, electrical poling, or thermal annealing. However, electrospinning requires long periods of time to form sufficiently thick PVDF nanofiber scaffolds and requires extremely high voltages to form scaffolds with enhanced piezoelectric properties, which limits the number of usable substrates, thus restricting the integration and use of electrospun PVDF scaffolds into wearable textile platforms. In this work, we propose a facile processing technique to airbrush PVDF−trifluoroethylene (TrFE) nanofiber scaffolds directly onto textile substrates. We tune the polymer concentration (4, 6, and 8 wt %) and the spray distance (5, 12.5, and 20 cm) to understand their effects on the morphology and crystal structure of the fibrous scaffolds. The characterization results show that increasing the polymer wt % encourages the formation of fibrous morphologies and a β-phase crystal structure. We then demonstrate how the airbrushed PVDF−TrFE scaffolds can be easily integrated onto conductive inkjet-printed nonwoven textile substrates to form airbrushed piezoelectric textile devices (APTDs). The APTDs exhibit maximum open-circuit voltages of 667.1 ± 162.1 mV under tapping and 276.9 ± 59.0 mV under bending deformations. The APTDs also show an areal power density of 0.04 μW/cm 2 , which is 40× times higher compared to previously reported airbrushed PVDF scaffolds. Lastly, we sew APTDs into wearable textile platforms to create fully textile-integrated devices with applications in sensing a basketball shooting form.
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