Porous nanofibers and micro-pyramid structures array for high-performance flexible pressure sensors

[Display omitted] Flexible pressure sensors have attracted extensive research interest as smart wearable devices’ core components. However, developing flexible pressure sensors with high sensitivity and wide pressure detection range remains a great challenge. Utilizing electrospinning and mould transfer technology, this paper presents a novel ‘sandwich’ flexible pressure sensor composed of a sensitive layer of poly (lactic acid) (PLA) porous nanofiber network film and electrodes made of polydimethylsiloxane (PDMS) micro-pyramid structure array film. Through ultrasonic treatment, carbon black particles penetrate into the PLA porous nanofiber film, which effectively enhances the conductivity of the PLA film. Due to the complex conductive pathways formed by the ultra-high specific surface area of the PLA porous nanofibers and the three-dimensional amplification structure of the PDMS micro-pyramid arrays, the sensor has a high sensitivity of 54.06 kPa−1, a wide detection range of 0–56 kPa, an ultra-low detection limit of 2.5 Pa and excellent durability (10000 cycles). Impressively, the sensor is able to accurately monitor various physiological activities of the human body in real time, which is believed to be a strong impetus for the development of the next generation of wearable products.