Arrayed Micropillar Ionic Film Iontronic Flexible Pressure Sensor and Its Wearable Sensing Applications

Flexible pressure sensors serve as core sensing components for wearable health monitoring systems, electronic skins for soft robots, and flexible human-machine interaction devices. Benefiting from the interfacial electric double-layer polarization effect, iontronic sensing delivers far higher pressure response sensitivity than conventional parallel-plate capacitive sensors, endowing it with distinctive advantages in the detection of weak physiological signals. Nevertheless, current dense ionic thin-film dielectric layers suffer from limited deformation space under compression and poor low-pressure sensing capability. Mainstream high-precision micropillar arrays are fabricated via photolithography, 3D printing, and metal etching molds, which require costly equipment and complicated fabrication procedures, making large-area mass production unfeasible. Random frosted concave-convex microstructures feature disordered dimensions, leading to severe device hysteresis and narrow linear ranges, which fail to achieve ultrahigh sensitivity alongside a wide pressure detection range simultaneously. To address the aforementioned multiple bottlenecks, this paper proposes a low-cost resin template replication process to fabricate TPU-based ionic thin-film dielectric layers with ordered micropillar array microstructures. Combined with inkjet-printed silver conductive PI flexible electrodes, an iontronic flexible pressure sensor with a sandwich layered structure is constructed. Multi-dimensional investigations including microscopic morphology characterization, electromechanical sensing performance calibration, and human wearable application tests are systematically implemented to thoroughly elucidate the synergistic enhancement mechanism of the arrayed micropillars. Test results demonstrate that the effective pressure detection range of the sensor spans 0-1038 kPa, accommodating ultra-low pressures such as pulse signals as well as medium-to-high-pressure loads including joint bending. The sensitivity reaches 23.27 kPa^-1 within the low-pressure range of 0-200 kPa and remains stable at 3.52 kPa^-1 in the high-pressure range of 200-1038 kPa, with piecewise linear fitting correlation coefficients of 0.93 and 0.96 respectively. Both the response time and recovery time of the device are 40 ms, and the hysteresis error throughout the loading-unloading cycle is merely 2.62%. After 20,000 consecutive cyclic loading-unloading tests, the peak capacitance output only decays by 5.1%, verifying outstanding mechanical fatigue resistance and electrical stability. Validations in multi-scenario applications prove that the sensor can accurately capture human physiological and motion signals including radial artery pulses, laryngeal deformation induced by multi-syllable vocalization, and multi-angle bending of fingers and elbow joints, suitable for home-based health monitoring, quantitative rehabilitation training, flexible tactile interaction and other scenarios. The entire fabrication process eliminates high-precision micro-nano processing equipment such as photolithography systems, plasma etchers and 3D printers; only general chemical raw materials and conventional laboratory instruments are adopted. The reusable templates enable low manufacturing costs and large-area coating forming, offering a novel low-cost technical solution for the engineering implementation and industrialization of high-performance iontronic flexible pressure sensors.