The tremendous progress of the wearable intelligent system has brought an urgent demand for flexible pressure sensors, especially for those possessing high sensing performances, simple manufacture technology, and efficient integration. In this work, hierarchical core-shell piezoresistive yarns (HCPYs), which contain internal silver-plated nylon electrodes and surface microporous structured carbon nanotubes (CNTs)/thermoplastic polyurethane (TPU) sensing layer, are designed and manufactured via facile wet-spinning accompanied by a water vapor coagulating bath. The obtained HCPY can either be inserted into traditional textiles to assemble a single-pressure sensor, or be woven into a textile-based flexible pressure sensors array with expected size and resolution, without compromising their comfort, breathability, and three-dimensional (3D) conformability. Simultaneously, to further enhance the sensing performance, the surface microporous structures of HCPYs are optimized by altering the treatment humidity and exposure time during the process of water vapor-induced phase separation. The wearable pressure sensors assembled by the optimal HCPY achieved a high sensitivity up to 84.5 N-1, a good durability over 5000-cycle tests, a fast response time of 2.1 ms, and a recovery time of 2.4 ms. Moreover, the wearable pressure sensors have been successfully used to monitor physical signals and human motions. The textile-based flexible pressure sensors array has also been seamlessly integrated with sportswear to detect movements of the elbow joint and map spatial pressure distribution, which makes HCPY a promising candidate for constructing next-generation wearable electronics.
Keywords: hierarchical core–shell piezoresistive yarns; modified wet-spinning; surface microporous structures; textile-based pressure sensors array; wearable pressure sensor.