A novel
porous polydimethylsiloxane (PDMS)-based capacitive pressure
sensor was fabricated by optimizing the dielectric layer porosity
for wide-range pressure sensing applications in the sports field.
The pressure sensor consists of a porous PDMS dielectric layer and
two fabric-based conductive electrodes. The porous PDMS dielectric
layer was fabricated by introducing nitric acid (HNO3)
into a mixture of PDMS and sodium hydrogen bicarbonate (NaHCO3) to facilitate the liberation of carbon dioxide (CO2) gas, which induces the creation of porous microstructures within
the PDMS dielectric layer. Nine different pressure sensors (PS1, PS2,...,
PS9) were fabricated in which the porosity (pore size, thickness)
and dielectric constant of the PDMS dielectric layers were varied
by changing the curing temperature, the mixing proportions of the
HNO3/PDMS concentration, and the PDMS mixing ratio. The
response of the fabricated pressure sensors was investigated for the
applied pressures ranging from 0 to 1000 kPa. A relative capacitance
change of ∼100, ∼323, and ∼485% was obtained
by increasing the curing temperature from 110 to 140 to 170 °C,
respectively. Similarly, a relative capacitance change of ∼170,
∼282, and ∼323% was obtained by increasing the HNO3/PDMS concentration from 10 to 15 to 20%, respectively. In
addition, a relative capacitance change of ∼94, ∼323,
and ∼460% was obtained by increasing the PDMS elastomer base/curing
agent ratio from 5:1 to 10:1 to 15:1, respectively. PS9 exhibited
the highest sensitivity over a wide pressure sensing range (low-pressure
ranges (<50 Pa), 0.3 kPa–1; high-pressure ranges
(0.2–1 MPa), 3.2 MPa–1). From the results,
it was observed that the pressure sensors with dielectric layers prepared
at relatively higher curing temperatures, higher HNO3 concentrations,
and higher PDMS ratios resulted in increased porosity and provided
the highest sensitivity. As an application demonstrator, a wearable
fit cap was developed using an array of 16 pressure sensors for measuring
and mapping the applied pressures on a player’s head while
wearing a helmet. The pressure mapping aids in observing and understanding
the proper fit of the helmet in sports applications.