Inspired by the sensory organs of spiders, crack-based strain sensors are flexible sensors fabricated by depositing a thin layer of metal onto a stretchable polymer. However, to date, most studies on crack-based sensors have considered only linear strain, even when bending is considered, which do not analyze how sensor resistance depends on complex strains (linear, convex, and concave). For each given type of strain, this study examined how the distance between cracks depends on the crack direction. This study also analyzed how the crack-generation mechanism depends on the relation between film-bending axis and crack direction. Thus, a device was proposed herein to test the crack-based sensors and demonstrate how this device can be used to measure the bending direction.
Studies on wearable sensors that monitor various movements by attaching them to a body have received considerable attention. Crack-based strain sensors are more sensitive than other sensors. Owing to their high sensitivity, these sensors have been investigated for measuring minute deformations occurring on the skin, such as pulse. However, existing studies have limited sensitivity at low strain range and nonlinearity that renders any calibration process complex and difficult. In this study, we propose a pre-strain and sensor-extending process to improve the sensitivity and linearity of the sensor. By using these pre-strain and sensor-extending processes, we were able to control the morphology and alignment of cracks and regulate the sensitivity and linearity of the sensor. Even if the sensor was fabricated in the same manner, the sensor that involved the pre-strain and extending processes had a sensitivity 100 times greater than normal sensors. Thus, our crack-based strain sensor had high sensitivity (gauge factor > 5000, gauge factor (GF = (△R/R0)/ε), linearity, and low hysteresis at low strain (<1% strain). Given its high sensing performance, the sensor can be used to measure micro-deformation, such as pulse wave and voice.
Development of flexible strain sensors that can be attached directly onto the skin, such as skin-mountable or wearable electronic devices, has recently attracted attention. However, such flexible sensors are generally exposed to various harsh environments, such as sweat, humidity, or dust, which cause noise and shorten the sensor lifetimes. This study reports the development of a nano-crack-based flexible sensor with mechanically, thermally, and chemically stable electrical characteristics in external environments using a novel one-step laser encapsulation (OLE) method optimized for thin films. The OLE process allows simultaneous patterning, cutting, and encapsulating of a device using laser cutting and thermoplastic polymers. The processes are simplified for economical and rapid production (one sensor in 8 s). Unlike other encapsulation methods, OLE does not degrade the performance of the sensor because the sensing layers remain unaffected. Sensors protected with OLE exhibit mechanical, thermal, and chemical stability under water-, heat-, dust-, and detergent-exposed conditions. Finally, a waterproof, flexible strain sensor is developed to detect motions around the eye, where oil and sweat are generated. OLE-based sensors can be used in several applications that are exposed to a large amount of foreign matter, such as humid or sweaty environments.
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