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Thin Encapsulated Flexible Pressure Sensor Suitable for Clothing Pressure Sensing Manikin

Yizhou Qi,Tingjiang Li,Bin Wu,Xiaowen Fan,Keai Ma,Kang Chen,Jinzhong Zhang,Qingwen Zhou,Weixin Zhou,Bolin Zheng,Huiyu Sun,Ge Shi

Published 2025 in IEEE Sensors Journal

ABSTRACT

The demand for flexible pressure sensors suitable for manikin has been driven by the need for clothing pressure sensing in real human wearing scenarios. This work develops a flexible pressure sensor characterized by thin thickness, sensitivity to low clothing pressure, and an array structure for manikin. The sensor features a “sandwich” structure, comprising a sensitive layer, an electrode layer, and an encapsulation layer. Fabrication methods based on laser cutting and thermal pressing are developed to manufacture the flexible pressure sensor. The resulting device exhibits reduced thickness with enhanced encapsulation, stability, and reliability, ensuring robustness during operation and enabling in situ measurement of clothing pressure. The piezoresistive material’s dual-layer stacked structure enables the sensor to exhibit high linearity ( $R^{2}$ = 95.8%) in sensitivity to low pressures (<2 kPa). Subsequently, static, dynamic, and high-humidity clothing pressure measurements performed on a manikin demonstrate that our flexible pressure sensor can effectively measure clothing pressure distribution across different regions of the manikin (chest, back, and arms) and maintain stable and accurate clothing pressure measurements during manikin movement and in high-humidity environments. The sensor has been identified as a promising candidate for integration into sensing systems of clothing pressure manikin.

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