Highly stretchable, sensitive and wide linear responsive fabric-based strain sensors with a self-segregated carbon nanotube (CNT)/Polydimethylsiloxane (PDMS) coating

Flexible strain sensors have received increasing attention with the development of wearable electronic devices. However, integrating wide strain detection range, high sensitivity while maintaining relatively wide linear response range for such sensor system still remain a challenge. A fabric based flexible sensor (S-CNT/PDMS-F) was designed and fabricated, and the sensor can simultaneously achieve high sensitivity, wide linear response and strain detection range by combining self-segregated carbon nanotube (CNT)/polydimethylsiloxane (PDMS) composites and elastic medical bandage. It has been observed that this new sensor system can achieve a high sensitivity with a gauge factor of 615, a large linear responsive range of 0–100% strain (R2 ​= ​0.993) and a wide strain detection range of ∼ 200%, which is superior to almost all the reported CNT/PDMS flexible strain sensors. Compared to the similar fabric based strain sensor system deploying non self-segregated structure (C-CNT/PDMS-F), our S-CNT/PDMS-F demonstrates higher electrical conductivity and lower electrical percolation threshold and response time of 55 ​ms, as well as more stable and repeatable performance under cyclic loading conditions. The capability of the sensors in monitoring physiological activities and weight distribution has also been demonstrated.