Facile Fabrication of a Highly Sensitive and Robust Flexible Pressure Sensor with Batten Microstructures

As the foremost component of wearable devices, flexible pressure sensors require high sensitivity, wide operating ranges, and great stability. In this paper, a pressure sensor comprising a regular batten microstructure active layer is presented. First, the influences of the dimensional parameters of the microstructures on the performances of the sensors were investigated by the mechanical finite element method (FEM). Then, parameters were optimized and determined based on the results of this investigation. Next, active layers were prepared by molding multiwalled carbon nanotube/polyurethane (MWCNT/PU) conductive composite using a printed circuit board template. Finally, a resistive flexible pressure sensor was fabricated by combining an active layer and an interdigital electrode. With advantages in terms of the structure and materials, the sensor exhibited a sensitivity of up to 46.66 kPa(−1) in the range of 0–1.5 kPa and up to 6.67 kPa(−1) in the range of 1.5–7.5 kPa. The results of the experiments show that the designed flexible pressure sensor can accurately measure small pressures and realize real-time human physiological monitoring. Furthermore, the preparation method has the advantages of a low cost, simple design, and high consistency. Thus, it has potential to promote the development of flexible sensors, wearable devices, and other related devices.