Highly Sensitive and Wide Detection Range Thermoplastic Polyurethane/Graphene Nanoplatelets Multifunctional Strain Sensor with a Porous and Crimped Network Structure

High-performance flexible strain sensors have tremendous potential applications in wearable devices and health monitoring. However, developing a flexible strain sensor with high sensitivity over a wide strain range remains a significant challenge. In this study, a fibrous membrane with a porous and crimped structure was designed as the substrate material for TPU/GNPs flexible strain sensors. This structural design effectively balances sensitivity with the strain range. The TPU-PEO fibrous membrane prepared using electrospinning with water washing, resulted in a porous fibrous membrane with a TPU framework. Subsequently, the fibrous membrane was subjected to anhydrous ethanol stimulation to obtain a porous and crimped network structure. GNPs were modified on the TPU fibrous membrane through ultrasonic treatment. The produced flexible strain sensor exhibited high sensitivity (GF = 4047.5) within a large strain range (350%) and demonstrated excellent sensing performance, stability, and durability (>10,000 cycles). It not only captured basic movements but also efficiently recognized and measured bending angles, enabling a more sophisticated human–machine interaction experience. This advancement opens up possibilities for future intelligent wearable technology and human–machine interaction, contributing to the evolution of these fields.