Sponge-Hosting Polyaniline Array Microstructures for Piezoresistive Sensors with a Wide Detection Range and High Sensitivity

The development of highly elastic spongy con-ductors is attractive for use in piezoresistive sensors due to their low cost, easy fabrication, and wide sensing range. However, the combination of high sensitivity and broad sensing range in a single piezoresistive sensor, though highly demanded, is challenging because they are contradictory in principle. Herein, a highly elastic spongy conductor with sponge-hosting polyaniline (PANI) fluff- like array microstructures is fabricated through cryopolymerization. The as-obtained sponge-hosting conductors exhibited an excellent elasticity under high compression strain and stress of up to 80% and 101 kPa, respectively, covering typical deformation ranges for detecting complex human activities. Benefiting from the presence of the sponge-hosting fluff-like PANI arrays, the as-prepared sponge-hosting conductors for piezoresistive sensors possessed a high sensitivity of 0.54 kPa(-1 )in a broad pressure range of 0.1-101 kPa, ascribing to the formation of the sponge-hosting fluff arrays with graded conductive network structures of array contacts and sponge-skeleton contacts at low and high compressions, respectively. As a result, the as-assembled piezoresistive sensors were demonstrated for tactile sensing and human-motion monitoring. This work reveals new approaches for tailored fabrication of sponge-hosting conducting polymers with tunable fluff-like microstructures for highly sensitive and wide-range wearable piezoresistive sensors.