Stretchable sensors are a class of materials with applications across research fields from healthcare to structural engineering. Despite the extensive research aiming to improve the performance of individual materials or components, stretchable sensor devices are difficult to implement because conventional electronic components, mainly used for processing, which are rigid, have to make contact with soft components reliable enough to withstand real-world usage.
This thesis introduces a method for creating electrical contacts that can be robustly attached onto soft, stretchable conductive polymer composites on one side and soldered to metal wires on the other side. Mechanically robust electrical contacts were developed to interface (soft) silicone-based strain sensors with conventional (hard) solid-state electronics using a nanoporous silicon-copper contact. Contacts are mounted on custom-made and commercial soft strain sensitive silicone sensors. The contacts are shown to be reliable under large deformations, then compared with a commonly used alternative under real-world strain conditions. The layered structure of the device creates a complex electronic component deriving from the silicon-copper Schottky junction.
This thesis tests the versatility of the technology through a series of real-world applications. The silicon-copper contacts were used to produce a series of proof-of-concept devices, including a wearable respiration monitor, leg band for exercise monitoring, and squeezable ball to monitor rehabilitation of patients with hand injuries or neurological disorders. The sensor is shown to operate and detect multiple modes of motion regardless of placement on the body.
Next, a proof-of-concept device was employed to measure hand grip strength. The optimized sensor can detect grip strength with high sensitivity. The hardness of the device was shown to increase sensitivity when healthy humans performed manual exercises and completed digital tasks. Providing patients with these devices can help
monitor their rehabilitation following hand injuries or neurological disorders. This can be done through self-led at-home therapy which has been shown to improve treatment, engagement, long-term lifestyle adherence, while avoiding repeated visits to clinics which plays an important role in frequency of therapy, effectiveness, and accessibility.Open Acces
