Wireless Rehabilitation Training Sensor Arrays Made with Hot Screen-Imprinted Conductive Hydrogels with a Low Percolation Threshold

Herein, we propose a highly sensitive wireless rehabilitation training ball with a piezoresistive sensor array for patients with Parkinson’s disease (PD). The piezoresistive material is a low percolation threshold conductive hydrogel which is formed with polypyrrole (PPy) nanofibers (NFs) as a conductive filler derived from a polydopamine (PDA) template. The proton acid doping effect and molecular template of PDA are essential for endowing PPy NFs with a high aspect ratio, leading to a low percolation threshold (∼0.78 vol %) and a low Young’s 004Dodulus of 37.69 kPa and hence easy deformation. The piezoresistive sensor exhibited a static and dynamic stability of 10,000 s and 15,000 cycle times, respectively. This stability could be attributed to the increased hydrophilicity of conductive fillers, enhancing the interfacial strength between the conductive filler and the matrix. The interaction between the PDA-PPy NFs and the hydrogel matrix endows the hydrogel with toughness and ensures the stability of the device. Additionally, the microdome structure of the conductive hydrogel, produced by hot screen-imprinting, dramatically improves the sensitivity of the piezoresistive sensor (∼856.14 kPa–1). The microdome conductive hydrogel can distinguish a subtle pressure of 15.40 Pa compared to the control hydrogel without a microstructure. The highly sensitive piezoresistive sensor has the potential to monitor the hand-grip force, which is not well controlled by patients with PD. The rehabilitation training ball assembled with a sensor array on the surface and a wireless chip for communication inside is built and used to monitor the pressure in real time through the WeChat applet. Thus, this work has significantly broadened the application of hydrogel-based flexible piezoresistive sensors for human activity monitoring, which provides a promising strategy to realize next-generation electronics.