Open Access Article
Jian
Mao
abc,
Zidong
He
*bc,
Yuanzhao
Wu
bc,
Jinwei
Cao
f,
Shijing
Zhao
bc,
Bin
Chen
abc,
Jie
Shang
bc,
Yiwei
Liu
*bcd and
Run-Wei
Li
*bcde
aFaculty of Electrical Engineering and Computer Science, Ningbo University, Ningbo, Zhejiang 315211, China
bCAS Key Laboratory of Magnetic Materials and Devices, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, Zhejiang 315201, China. E-mail: hezidong@nimte.ac.cn; liuyw@nimte.ac.cn; runweili@nimte.ac.cn
cZhejiang Province Key Laboratory of Magnetic Materials and Application Technology, Ningbo Institute of Materials Technology and Engineering, Chinese Academy of Sciences, Ningbo, Zhejiang 315201, China
dCenter of Materials Science and Optoelectronics Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
eSchool of Future Technology, University of Chinese Academy of Sciences, Beijing 100049, China
fInnovative Center for Flexible Devices (iFLEX), Max Planck-NTU Joint Lab for Artificial Senses, School of Materials Science and Engineering, Nanyang Technological University, 50 Nanyang Avenue, 639798, Singapore
First published on 5th June 2024
Flexible strain sensors are an essential component of electronic skin as they are capable of sensing various physiological signals from the human body. They can be used to monitor human health and performance during exercise. However, most currently available strain sensors cannot simultaneously detect both small and large strains on the human skin during movement. In this study, we propose a planar, inductive strain sensor based on liquid metal putty with exceptional elasticity. This sensor can detect both large and small strains: it can measure strains of up to 300% and detect those as low as 0.05% while exhibiting excellent stability (more than 5000 stretch–release cycles) and consistency in terms of variations in inductance (a maximum change of only 1.2%). It also performs well under bending and folding conditions. We also investigated methods to enhance the sensitivity of the sensor under stretching conditions, and used the results to develop a system to monitor signals of human movement based on techniques of wireless transmission and signal processing. This system can capture changes in the magnitude of strain on the skin during human movement, and can be used to monitor various human activities, including respiratory signals, swallowing, and the movements of the joints. Due to these features, the proposed system offers significant potential for use in applications of health and motion monitoring.
The amplitude of changes on the surface of the skin caused by various physiological signals can vary significantly. For instance, the strain on the surface of the skin varies by less than 0.5% in cases of swallowing, vibrations of the vocal cord, and the movements of the chest during breathing. In contrast, changes in the skin strain can exceed 55% due to the movement of larger joints, such as those of the arms and knees.5 This highlights the need for sensors that can accurately detect and differentiate between strains of various magnitudes on the surface of the skin.
Researchers have recently developed strain sensors that can be classified based on their principles of operation as resistive,6 capacitive,7 and inductive sensors.8 Some of these sensors have exhibited excellent capabilities for the detection of small strains,9–11 while others have been shown to possess exceptional flexibility that enables them to monitor a wide range of human activities.12–15 However, the excessive or prolonged stretching of certain sensors, such as resistive sensors, can result in fatigue-induced damage to materials within them, as has been reported in ref. 16 and 17. Furthermore, some capacitive sensors have limited immunity to interference owing to their low initial capacitance, where this can hinder their use to detect weak signals as well as their high-density integration, as has been reported in ref.18.
In comparison with the above-mentioned sensors, another type of flexible inductive sensors has sparked widespread research due to such advantages as a high resolution, wide range of detection, and good stability. The most commonly used flexible inductive sensors include eddy current sensors,19 mutual inductance sensors,20 and self-inductance sensors.21,22 When a self-inductance sensor is deformed, its structure changes, and this results in a change in its self-inductance. The sensor requires only a single coil to carry out its sensing function, where the inductance of the coil varies with its geometric shape, and leads to changes in the inductance of the sensor when the coil is deformed.23 The self-inductance sensor has a relatively straightforward structure due to this principle, which provides better structural stability. This makes it highly suitable for monitoring various physiological signals of the human body.24 Despite their numerous advantages, research on high-performance, stretchable self-inductance sensors remains limited.
Inductive sensors composed of elastic fabrics traditionally use copper wires that are sewn into place. However, copper wires are rigid and have limited flexibility, where this makes them unsuitable for use in highly deformable sensors.25,26 Liquid metal is widely known for its excellent conductivity, biocompatibility, and exceptional deformability. This makes it a highly promising material for use in flexible and elastic sensors, and it has thus garnered significant interest from researchers.27,28 The widespread application of liquid metal for the production of diverse flexible and elastic electronic devices has provided a novel avenue for manufacturing sensors with ultra-high deformability.29 Researchers have attempted to infuse liquid metal into 3D-printed elastic casings to create soft, spring-like electronic devices that are capable of detecting the degree of flexion in human fingers and in soft robots. However, this method leads to sensors that are susceptible to deformation due to their weight, struggle to maintain their structural integrity, fail to establish optimal contact with the skin, and encounter challenges in detecting minor strains.30,31 A practical strategy for creating microfluidic channels within the elastic material and subsequently injecting liquid metal to form planar coils has also been developed. However, it is important to ensure adequate encapsulation to prevent the leakage of liquid metal from the microfluidic channels.32,33 The intricate manufacturing processes associated with the aforementioned methods significantly limit the widespread application of liquid metal-based flexible and elastic strain sensors.
In this study, we propose a hyperelastic, planar, inductive strain sensor that uses fully oxidized liquid metal putty as the material of the coil. The excellent printability and high conductivity of liquid metal putty make it an ideal choice for use as a conductive material. Ecoflex was used as the elastic substrate on which the liquid metal putty was printed by using the scratch-off method, followed by the installation of lead wiring and encapsulation. Sensors made by using this method do not require complex and expensive manufacturing processes. Furthermore, we analyzed the impact of the shape and spacing of the coil, the width of the wire, and the number of turns on the sensitivity of the sensor to determine the optimal design parameters. The sensors yielded exceptional results under both large (300%) and small strains (0.05%) while exhibiting remarkable stability and durability. Fig. 1 illustrates a wearable system for the wireless monitoring of human activity by using this sensor. The system comprises a hyperelastic, planar, inductive strain sensor that uses liquid metal putty, signal processing circuitry, and a portable mobile display device. It can detect physiological signals from different parts of the human body when it is at rest and in motion, thus demonstrating its potential for use in wearable electronic devices.
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| Fig. 1 System for the wireless health monitoring of activities of the human body based on flexible, planar, inductive strain sensors. | ||
| LTotal = ∑Li + ∑Mi,j | (1) |
![]() | (2) |
![]() | (3) |
Eqn (2) and (3) express the self-inductance and the mutual inductance of a single wire segment, respectively. Li represents the self-inductance of an individual conductor and Mi,j represents the mutual inductance between parallel conductors. The length, width, and thickness of the conductor are denoted by l, w, and t, respectively. The literature has confirmed that the change in the length of the conductor in the coil has a more significant impact than changes in its width and thickness during stretching.34 This results in an overall increase in its inductance throughout the stretching process. The change in d (the spatial separation between parallel conductors), which is positively correlated with the variation in the mutual inductance ΔM, mainly determines the change in the inductance of the coil during its entire process of deformation.24 The primary factors influencing d are the length and number of parallel straight conductors. The latter two variables are directly influenced by the structural parameters of the sensor, including its shape, the spacing between the lines, the line width, and the number of turns.
![]() | (4) |
We created several sensors to study the impact of the structural parameters of the coil on their sensitivity. The change in the inductance signal is denoted by ΔL, while L represents the initial inductance and ε indicates the applied strain. The effect of coils of different shapes on the sensitivity of the sensor was analyzed by using rectangular and circular coils. Both types of coils had identical specifications otherwise, including their size, number of turns, and the width of the wires and the spacing between them. The strain was increased from 0% under uniaxial stretching. Fig. 3(a) shows that the rectangular coil consistently exhibited a larger relative change in inductance than the circular coil at varying stretching-induced strains. As mentioned in the theoretical analysis above, the change in inductance occurred mainly owing to the parallel straight conductors. The sensitivity of the sensor increased with the length of its parallel straight conductors. Due to their structure, rectangular coils had a larger number of parallel straight conductors that were longer that those of the circular coil, and this led to a higher sensitivity. Therefore, we chose a rectangular structure for the sensor.
Next, we also investigated the impact of the spacing between the wires on the sensitivity of the sensor while fixing its size. Three wire spacings were tested—s = 1 mm, 1.5 mm, and 2 mm—while keeping the number of turns (N) fixed at five and the width of the wire (w) at 1 mm. The sensors were subjected to strains ranging from 0% to 100%, and their resulting sensitivities were compared. Three wire widths were tested—w = 0.5 mm, 1 mm, and 1.5 mm—while keeping the number of turns (N) fixed at five and the wire spacing (s) at 1 mm. The sensors were subjected to strains ranging from 0% to 100%, and their resulting sensitivities were compared. The observations showed that the sensitivity of the sensor decreased as the distance between the wires and their width increased (Fig. 3(b) and (c)). Using narrow wires with short spaces between them leads to an increase in the distance between the parallel straight conductors in the coil, thus elongating each conductor. This in turn increases the mutual inductance and sensitivity of the sensor.
To examine the influence of the number of turns (N) of the coil on the sensitivity of the sensor, we tested sensors with four values of turns of the coil (N = 5, 7, 9, and 11), with the width of the wire (w) fixed at 0.5 mm and the spacing between the wires fixed at 1 mm. The results consistently demonstrated an improvement in the sensitivity of the sensor as the number of turns of the coil increased (refer to Fig. 3(d)). This was obtained owing to the larger number of turns, which introduced additional segments of the parallel straight conductor that generated mutual inductance. This led to substantial changes in the mutual inductance ΔM across different sections of the sensor. The experimental findings regarding the effects of the spacing between the wires (s), their width (w), and the number of turns (N) of the coil are summarized in Table 1. It shows that the sensor exhibited the highest sensitivity when N = 11, W = 0.5 mm, and S = 1 mm. We used these parameters as the standard for designing sensors.
| No of coils | Width (mm) | Spacing (mm) | GF |
|---|---|---|---|
| 5 | 1.0 | 1 | 0.248 |
| 1.0 | 1.5 | 0.227 | |
| 1.0 | 2 | 0.211 | |
| 5 | 0.5 | 1 | 0.296 |
| 1.0 | 1 | 0.248 | |
| 1.5 | 1 | 0.224 | |
| 5 | 0.5 | 1 | 0.296 |
| 7 | 0.5 | 1 | 0.335 |
| 9 | 0.5 | 1 | 0.355 |
| 11 | 0.5 | 1 | 0.371 |
The changes in the relative inductance of the sensor were tested under bending and folding conditions (Fig. 4(f)). Electromagnetic simulations of the sensor were also performed by using finite element analysis software. The results showed that the inductance of the sensor decreased as its degrees of bending and folding increased. The degree of bending was expressed in terms of the height of the upward bulge at the center of the sensor. Specifically, there is a direct relationship between this height parameter and the degree of bending: smaller height values correspond to less bending, while increasing height values indicate more bending. The results of the simulations in Fig. S4 (ESI†) demonstrate that a reduction in the inductance of the sensor was caused by the cancellation of the magnetic fields generated by the two halves of its coil. Similar results were obtained from the experiments. When sensors with varying radii of curvature were bent, their inductances increased proportionally to the radius of curvature (Fig. 4(g)). During the folding test, the sensor was secured to a rectangular frame-holder and gradually unfolded from 0° to 180°, and this led to a gradual increase in its inductance (Fig. 4(h)). These experimental results were in agreement with those of the simulations, suggesting that the sensor was reliable under folding and bending conditions, and thus has the potential to detect the opening and closing of certain joints of the human body.
Fig. 5(d) shows the validation tests performed on a mannequin by using the proposed detection system. The sensor was placed on the mannequin's chest to monitor its expansion and contraction during breathing. Various volumes of air were delivered to the mannequin by using a respiratory bag to simulate different states of breathing. Fig. 5(e) shows that the detection system was able to accurately distinguish between different breathing states of the mannequin. Video S1 (ESI†) shows a demonstration of this ability.
Fig. 6(c) and (d) show the system's ability to monitor changes in the movements of the knee and the elbow. We tested its ability to detect different states of motion of the legs by placing sensors on the knees. The results show that the system was able to accurately differentiate between the movements of the legs under normal and quick motion. Furthermore, it detected the opening and closing of the elbow joint when the sensor was placed at the appropriate position. These results show that our system can accurately detect motion signals from multiple parts of the body when it is stationary, and can monitor changes in the physiological signals during movement. We also tested the system's ability to differentiate among the patterns of human respiration during running, walking, and stationary states (Fig. 6(e)), and found it to be accurate (Fig. 6(f)). Video S2 (ESI†) demonstrates its effectiveness in detecting real-time breathing during human movement. The reduction in its sensing value was a result of the increased rate of breathing while running. This higher rate of breathing prevented the sensor from returning to its original state before being deformed again by the rise and fall of the chest cavity. Furthermore, as demonstrated in Video S3 (ESI†), our system could detect changes in the bending of the leg during walking (Fig. 6(g)).
:
1 by weight. Gallium and indium were mixed in a ratio of 74.5
:
25.5 by weight, then heated and stirred at 60 °C for 30 minutes to obtain liquid metal putty (LM-P). (ii) To produce an elastomeric substrate film, pre-configured ecoflex00-30 is poured into a spin coater. The film is then placed on the coater and a mask plate is placed on the surface of the elastic substrate. Liquid metal play dough is applied to the mask plate and a winding pattern is formed on the elastic substrate using the coater. (iii) Attach copper lead wires to each end of the coil to act as electrodes. Secure the electrodes in place by applying ecoflex00-30 to the joints. Place the coil on a rotary coater and apply the ecoflex00-30 solution at 700 rpm. Cure the coil in an oven at 60 °C for 30 minutes.
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4ma00140k |
| This journal is © The Royal Society of Chemistry 2024 |