Ultra-Flexible, Breathable, and Robust PAN/MWCNTs/PANI Nanofiber Networks for High-Performance Wearable Gas Sensor Application

Wearable gas sensors have drawn great attention for potential applications in health monitoring, minienvironment detection, and advanced soft electronic noses. However, it still remains a great challenge to simultaneously achieve excellent flexibility, high sensitivity, robustness, and gas permeability, because of the inherent limitation of widely used traditional organic flexible substrates. Herein, an electrospinning polyacrylonitrile (PAN) nanofiber network was designed as a flexible substrate, on which an ultraflexible wearable gas sensor was prepared with in situ assembled polyaniline (PANI) and multiwalled carbon nanotubes (MWCNTs) as a sensitive layer. The unique nanofiber network and strong binding force between substrate and sensing materials endow the wearable gas sensor with excellent robustness, flexibility, and gas permeability. The wearable sensor can maintain stable NH₃ sensing performance while sustaining extreme bending and stretching (50% of strain). The Young's modulus of wearable PAN/MWCNTs/PANI sensor is as low as 18.9 MPa, which is several orders of magnitude smaller than those of reported flexible sensors. The water vapor transmission rate of the sensor is 0.38 g/(cm² 24 h), which enables the wearing comfort of the sensor. Most importantly, due to the effective exposure of sensing sites as well as the heterostructure effect between MWCNTs and PANI, the sensor shows high sensitivity to NH₃ at room temperature, and the theoretical limit of detection is as low as 300 ppb. This work provides a new avenue for the realization of reliable and high-performance wearable gas sensors.