Highly Stretchable and Sensitive Strain Sensor with Porous Segregated Conductive Network

Flexible strain sensors based on elastomeric conductive polymer composites (ECPCs) play an important role in wearable sensing electronics. However, the achievement of good conjunction between broad detection range and high sensitivity is still challenging. Herein, a highly stretchable and sensitive strain sensor was developed with the formation of porous segregated conductive network in the carbon nanotube/thermoplastic polyurethane composite via a facile and nontoxic compression-molding plus salt-leaching method. The strain sensor with porous segregated conductive network exhibited perfect combination of ultrawide sensing range (800% strain), large sensitivity (gauge factor of 356.4), short response time (180 ms) and recovery time (180 ms), as well as superior stability and durability. The integrated porous structure intensifies the deformation of segregated conductive network when tension strain is applied, which benefits enhancement of the sensitivity. Our sensor could monitor not only subtle oscillation and physiological signals but also energetic human motions efficiently, revealing promising potential applications in wearable motion monitoring systems. This work provides a unique and effective strategy for realizing ECPCs based strain sensors with excellent comprehensive sensing performances.