Inkjet printing technology for flexible pressure sensors

Tese de Doutoramento Ciência e Engenharia de Polímeros e Compósitos.

Patterned CNT-PDMS nanocomposites for flexible pressure sensors

This paper reports the fabrication process and characterization of a flexible pressure sensor based on polydimethylsiloxane (PDMS) and multi-walled carbon nanotubes (CNT-PDMS). The proposed approach relies on patterned CNT-PDMS nanocomposite strain gauges fabricated with SU-8 microstructures (with the micropatterns) in a low‑cost and simple fabrication process. This nanocomposite polymer is mounted over a PDMS membrane, which, in turn, lies on top of a PDMS diaphragm like structure. This configuration enables the PDMS membrane to bend when pressure is applied, thereby affecting the nanocomposite strain gauges, effectively changing their electrical resistance. Carbon nanotubes have several advantages such as excellent mechanical properties, high electrical conductivity and thermal stability. Furthermore, the measurement range of the proposed sensor can be adapted according to the application by varying the CNTs content and geometry of microstructure. In addition, the sensor’s biocompatibility, low cost and simple fabrication makes it very appealing for biomechanical strain sensing. The sensor’s sensitivity was about 0.073%ΔR/mmHg.

Flexible gastrointestinal motility pressure sensors based on aluminum thin-film strain-gauge arrays

This paper reports on an innovative approach to measuring intraluminal pressure in the upper gastrointestinal (GI) tract, especially monitoring GI motility and peristaltic movements. The proposed approach relies on thin-film aluminum strain gauges deposited on top of a Kapton membrane, which in turn lies on top of an SU-8 diaphragm-like structure. This structure enables the Kapton membrane to bend when pressure is applied, thereby affecting the strain gauges and effectively changing their electrical resistance. The sensor, with an area of 3.4 mm2, is fabricated using photolithography and standard microfabrication techniques (wet etching). It features a linear response (R2 = 0.9987) and an overall sensitivity of 2.6 mV mmHg−1. Additionally, its topology allows a high integration capability. The strain gauges’ responses to pressure were studied and the fabrication process optimized to achieve high sensitivity, linearity, and reproducibility. The sequential acquisition of the different signals is carried out by a microcontroller, with a 10-bit ADC and a sample rate of 250 Hz. The pressure signals are then presented in a user-friendly interface, developed using the Integrated Development Environment software, QtCreator IDE, for better visualization by physicians.

An Inter-digital Capacitive Electrode Modified as a Pressure Sensor

Inter-digital capacitive electrodes working as electric field sensors have been developed for touch panel applications. Evaluation circuits to convert variations in electric fields in such sensors into computer compatible data are commercially available. We report development of an Interdigital capacitive electrode working as a sensitive pressure sensor in the range 0-120 kPa. Essentially it is a touch/proximity sensor converted into a pressure sensor with a suitable elastomer buffer medium acting as the pressure transmitter. The performance of the sensor has been evaluated and reported. Such sensors can be made very economical in comparison to existing pressure sensors. Moreover, they are very convenient to be fabricated into sensor arrays involving a number of sensors for distributed pressure sensing applications such as in biomedical systems.

Conductive composites of natural rubber and carbon black for pressure sensors

Composites of natural rubber and carbon black have attracted great interest due to their technological applications. In this work natural rubber (NR) and carbon black (CB) were compounded, aiming the development of composites with good mechanical properties, processability and electrical conductivity for use as pressure sensors. The electrical conductivity changes from 10(-11) to 10(-2) S.cm(-1) depending on the percentage of CB in the composite. It was also observed that the conductivity varies reversibly and linearly with the applied pressure. The latter demonstrates that this material can be used as pressure sensors.

Design and development of new pressure sensors for aerodynamic applications

This artwork reports on two different projects that were carried out during the three years of Doctor of the Philosophy course. In the first years a project regarding Capacitive Pressure Sensors Array for Aerodynamic Applications was developed in the Applied Aerodynamic research team of the Second Faculty of Engineering, University of Bologna, Forlì, Italy, and in collaboration with the ARCES laboratories of the same university. Capacitive pressure sensors were designed and fabricated, investigating theoretically and experimentally the sensor’s mechanical and electrical behaviours by means of finite elements method simulations and by means of wind tunnel tests. During the design phase, the sensor figures of merit are considered and evaluated for specific aerodynamic applications. The aim of this work is the production of low cost MEMS-alternative devices suitable for a sensor network to be implemented in air data system. The last two year was dedicated to a project regarding Wireless Pressure Sensor Network for Nautical Applications. Aim of the developed sensor network is to sense the weak pressure field acting on the sail plan of a full batten sail by means of instrumented battens, providing a real time differential pressure map over the entire sail surface. The wireless sensor network and the sensing unit were designed, fabricated and tested in the faculty laboratories. A static non-linear coupled mechanical-electrostatic simulation, has been developed to predict the pressure versus capacitance static characteristic suitable for the transduction process and to tune the geometry of the transducer to reach the required resolution, sensitivity and time response in the appropriate full scale pressure input A time dependent viscoelastic error model has been inferred and developed by means of experimental data in order to model, predict and reduce the inaccuracy bound due to the viscolelastic phenomena affecting the Mylar® polyester film used for the sensor diaphragm. The development of the two above mentioned subjects are strictly related but presently separately in this artwork.

High precision pressure sensors based on SAW devices in the GHz range

In this paper, an AlN/free-standing nanocrystalline diamond (NCD) system is proposed in order to process high frequency surface acoustic wave (SAW) resonators for sensing applications. The main problem of synthetic diamond is its high surface roughness that worsens the sputtered AlN quality and hence the device response. In order to study the feasibility of this structure, AlN films from 150 nm up to 1200 nm thick have been deposited on free-standing NCD. We have then analysed the influence of the AlN layer thickness on its crystal quality and device response. Optimized thin films of 300 nm have been used to fabricate of one-port SAW resonators operating in the 10–14 GHz frequency range. A SAW based sensor pressure with a sensibility of 0.33 MHz/bar has been fabricated.

Advanced characterization of a coffee fermenting tank by multi-distributed wireless sensors: spatial interpolation and phase diagrams.

In coffee processing the fermentation stage is considered one of the critical operations by its impact on the final quality of the product. However, the level of control of the fermentation process on each farm is often not adequate; the use of sensorics for controlling coffee fermentation is not common. The objective of this work is to characterize the fermentation temperature in a fermentation tank by applying spatial interpolation and a new methodology of data analysis based on phase space diagrams of temperature data, collected by means of multi-distributed, low cost and autonomous wireless sensors. A real coffee fermentation was supervised in the Cauca region (Colombia) with a network of 24 semi-passive TurboTag RFID temperature loggers with vacuum plastic cover, submerged directly in the fermenting mass. Temporal evolution and spatial distribution of temperature is described in terms of the phase diagram areas which characterizes the cyclic behaviour of temperature and highlights the significant heterogeneity of thermal conditions at different locations in the tank where the average temperature of the fermentation was 21.2 °C, although there were temperature ranges of 4.6°C, and average spatial standard deviation of ±1.21ºC. In the upper part of the tank we found high heterogeneity of temperatures, the higher temperatures and therefore the higher fermentation rates. While at the bottom, it has been computed an area in the phase diagram practically half of the area occupied by the sensors of the upper tank, therefore this location showed higher temperature homogeneity

Advanced Characterisation of a Coffee Fermenting Tank by Multi-distributed Wireless Sensors: Spatial Interpolation and Phase Space Graphs

The fermentation stage is considered to be one of the critical steps in coffee processing due to its impact on the final quality of the product. The objective of this work is to characterise the temperature gradients in a fermentation tank by multi-distributed, low-cost and autonomous wireless sensors (23 semi-passive TurboTag® radio-frequency identifier (RFID) temperature loggers). Spatial interpolation in polar coordinates and an innovative methodology based on phase space diagrams are used. A real coffee fermentation process was supervised in the Cauca region (Colombia) with sensors submerged directly in the fermenting mass, leading to a 4.6 °C temperature range within the fermentation process. Spatial interpolation shows a maximum instant radial temperature gradient of 0.1 °C/cm from the centre to the perimeter of the tank and a vertical temperature gradient of 0.25 °C/cm for sensors with equal polar coordinates. The combination of spatial interpolation and phase space graphs consistently enables the identification of five local behaviours during fermentation (hot and cold spots).

Multi-distributed wireless sensors for monitoring a long distance transport in a reefer container

The study of the temperature gradients in cold stores and containers is a critical issue in the food industry for the quality assurance of products during transport and for minimising losses. This work presents an analysis of the temperatures during the refrigerated transport of 4,320 kg of blueberries in a reefer (set point temperature at ?1ºC) on a container ship from Montevideo (Uruguay) to Verona (Italy). The monitoring was performed by using semi-passive RFID loggers (TurboTag cards). The objective was to carry out a multi-distributed supervision using low-cost, wireless and autonomous sensors for the characterisation of the distribution and spatial gradients of temperatures during a long distance transport. Data analysis shows spatial (phase space) and temporal sequencing diagrams and reveals a significant heterogeneity of temperature at different locations in the container, which highlights the ineffectiveness of a temperature control system based on a single sensor, as is usually done.

Characteristics of Brillouin gain based distributed temperature sensors

A Brillouin-gain based distributed temperature sensor has been investigated experimentally and theoretically. The relation between Brillouin gain, input probe power and sensing length have been studied. The study shows that there is an optimum probe power providing a maximum Brillouin gain signal for a given sensing length.

Temperature non-uniformity in distributed temperature sensors

A study is presented of the effects of temperature non-uniformity in a distributed temperature sensor based on the temperature dependence of Brillouin gain in an optical fibre. The form of the Brillouin gain profile for a given temperature distribution is measured and successfully modelled.

Temperature non-uniformity in distributed temperature sensors

A study is presented of the effects of temperature non-uniformity in a distributed temperature sensor based on the temperature dependence of Brillouin gain in an optical fibre. The form of the Brillouin gain profile for a given temperature distribution is measured and successfully modelled.

Characteristics of Brillouin gain based distributed temperature sensors

A Brillouin-gain based distributed temperature sensor has been investigated experimentally and theoretically. The relation between Brillouin gain, input probe power and sensing length have been studied. The study shows that there is an optimum probe power providing a maximum Brillouin gain signal for a given sensing length.

High spatial and temporal resolution interrogation of fully distributed chirped fiber Bragg grating sensors

A novel interrogation technique for fully distributed linearly chirped fiber Bragg grating (LCFBG) strain sensors with simultaneous high temporal and spatial resolution based on optical time-stretch frequency-domain reflectometry (OTS-FDR) is proposed and experimentally demonstrated. LCFBGs is a promising candidate for fully distributed sensors thanks to its longer grating length and broader reflection bandwidth compared to normal uniform FBGs. In the proposed system, two identical LCFBGs are employed in a Michelson interferometer setup with one grating serving as the reference grating whereas the other serving as the sensing element. Broadband spectral interferogram is formed and the strain information is encoded into the wavelength-dependent free spectral range (FSR). Ultrafast interrogation is achieved based on dispersion-induced time stretch such that the target spectral interferogram is mapped to a temporal interference waveform that can be captured in real-Time using a single-pixel photodector. The distributed strain along the sensing grating can be reconstructed from the instantaneous RF frequency of the captured waveform. High-spatial resolution is also obtained due to high-speed data acquisition. In a proof-of-concept experiment, ultrafast real-Time interrogation of fully-distributed grating sensors with various strain distributions is experimentally demonstrated. An ultrarapid measurement speed of 50 MHz with a high spatial resolution of 31.5 μm over a gauge length of 25 mm and a strain resolution of 9.1 μϵ have been achieved.