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Low-Cost, Scalable Fabrication of All-Fabric Piezoresistive Sensors via Binder-Free, In-Situ Welding of Carbon Nanotubes on Bicomponent Nonwovens

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Abstract

Wearable piezoresistive sensors have shown enormous application prospects in flexible electronics and human–machine interfaces. However, current piezoresistive sensors suffer from common deficiencies including high fabrication cost, poor comfort and low attachment fastness of conductive substances on substrates, thereby impeding their large-scale production and practical use. Herein, a three-dimensional all-fabric piezoresistive sensor is reported based on coating multi-wall carbon nanotubes (MWCNTs) on bicomponent nonwovens composed of core-sheath fibers. The combination of core-sheath fibers with a heat-induced welding strategy greatly improves the adhesion fastness and stability of MWCNT network. The multi-layered all-fabric structure provides as-prepared sensors with high sensitivity (9.43% kPa−1 in 0–10 kPa and 0.076% kPa−1 in 20–120 kPa), wide pressure-sensing range (0–120 kPa), fast response/relaxation time (100 and 60 ms), good reproducibility and air permeability. Application of the sensor is demonstrated through the detection of human activities (such as pulse, cough and joint movements) and the wireless monitoring of forefinger bending. Moreover, our sensor is fabricated out of cost-effective materials, using scalable approach without using glue or binders. The method established in this work may provide an efficient strategy for the design and production of high-performance all-fabric piezoresistive sensors.

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The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Acknowledgements

Financial supports from the National Natural Science Foundation of China (Grant No. 32271378), Henan Key Laboratory of Medical and Protective Products (No. YDFH-2022-KF-02), and the Fundamental Research Funds for the Central Universities and Graduate Student Innovation Fund of Donghua University (CUSF-DH-D-2020019) are acknowledged.

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Authors and Affiliations

  1. State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Textiles, Donghua University, Shanghai, 201620, China

    Guangliang Tian, Jixia Deng, Wenhua Yu, Leihang Yang, Xiangyu Jin, Qinfei Ke & Chen Huang

  2. Shanghai Frontiers Science Center of Modern Textiles, Donghua University, Shanghai, 201620, China

    Yihan Shi & Yi Zhao

  3. Department of Respiratory Medicine, Shanghai Jiao Tong University Affiliated Sixth People’s Hospital, Shanghai, 200233, China

    Yi Lu

  4. Henan Key Laboratory of Medical and Protective Products, Henan Yadu Industry Co., Ltd., Xinxiang, 453000, China

    Yi Zhao & Chen Huang

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  1. Guangliang Tian
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Correspondence to Yi Lu, Qinfei Ke or Chen Huang.

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Tian, G., Shi, Y., Deng, J. et al. Low-Cost, Scalable Fabrication of All-Fabric Piezoresistive Sensors via Binder-Free, In-Situ Welding of Carbon Nanotubes on Bicomponent Nonwovens. Adv. Fiber Mater. 6, 120–132 (2024). https://doi.org/10.1007/s42765-023-00331-2

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