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Microcrack-Enhanced PEDOT:PSS Textile for Rapid-Response, Stable, and Breathable Wearable Sensors
Yuzhe Gu1,2, Zixuan Zhang1, Weilin Liu1
1College of Electronic and Optical Engineering, College of Flexible Electronics (Future Technology), Nanjing University of Posts and Telecommunications (NJUPT), Nanjing 210023, China.
ACS Sensors
|August 29, 2025
Summary
Researchers developed a new textile-based sensor using waterborne polyurethane (WPU) enhanced poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS). This flexible dry sensor offers high conductivity and sensitivity for wearable health monitoring applications.
Area of Science:
- Materials Science
- Polymer Chemistry
- Wearable Electronics
Background:
- High-performance, comfortable sensors are essential for real-time human health monitoring in wearable electronics.
- Existing sensors often face limitations in flexibility, comfort, and real-time monitoring capabilities.
Purpose of the Study:
- To fabricate a novel textile-based flexible dry sensor with enhanced conductivity and sensitivity.
- To investigate the effect of waterborne polyurethane (WPU) on poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS) for improved sensor performance.
- To evaluate the potential of the fabricated sensor for wearable body motion and electrocardiogram monitoring.
Main Methods:
- Synthesized WPU using a three-step acetaldehyde method.
- Fabricated a textile-based sensor by coating WPU-enhanced PEDOT:PSS onto polyester fabric.
- Optimized PEDOT:PSS/WPU composite conductivity through sulfuric acid treatment.
- Investigated the effect of prestretching on sensor sensitivity, stability, and water vapor transmission rate.
Main Results:
- Achieved a conductivity of 3000 S cm-1 for the PEDOT:PSS/WPU composite after sulfuric acid treatment.
- The resulting PW-coated fabric (PWF) exhibited a low resistance of 71.69 Ω sq.
- Prestretching induced microcracks, enhancing sensitivity (80 ms response at 400 Pa) and stability under compression cycles.
- PWF demonstrated a higher water vapor transmission rate (23.8 kg m-2 d-1) compared to pristine fabrics.
Conclusions:
- The developed textile-based flexible dry sensor shows excellent conductivity, sensitivity, and stability.
- Pre-stretching is a key process for optimizing sensor performance and breathability.
- The fabricated PWF holds significant promise for applications in wearable body motion and electrocardiogram monitoring.
