Ultrasoft Long-Lasting Reusable Hydrogel-Based Sensor Patch for Biosignal Recording

Here, we report an ultrasoft extra long-lasting, reusable hydrogel-based sensor that enables high-quality electrophysiological recording with low-motion artifacts. The developed sensor can be used and stored in an ambient environment for months before being reused. The developed sensor is made of a self-adhesive electrical-conductivity-enhanced ultrasoft hydrogel mounted in an Ecoflex-based frame. The hydrogel's conductivity was enhanced by incorporating polypyrrole (PPy), resulting in a conductivity of 0.25 S m. Young's modulus of the sensor is only 12.9 kPa, and it is stretchable up to 190%. The sensor was successfully used for electrocardiography (ECG) and electromyography (EMG). Our results indicate that using the developed hydrogel-based sensor, the signal-to-noise ratio of recorded electrophysiological signals was improved in comparison to that when medical-grade silver/silver chloride (Ag/AgCl) wet gel electrodes were used (33.55 dB in comparison to 22.16 dB). Due to the ultra-softness, high stretchability, and self-adhesion of the developed sensor, it can conform to the skin and, therefore, shows low susceptibility to motion. In addition, the sensor shows no sign of irritation or allergic reaction, which usually occurs after long-term wearing of medical-grade Ag/AgCl wet gel electrodes on the skin. Further, the sensor is fabricated using a low-cost and scalable fabrication process.