Fabrication of electrically conductive poly(styrene-b-ethylene-ran-butylene-b-styrene)/multi-walled carbon nanotubes composite fiber and its application in ultra-stretchable strain sensor

Although flexible polymer composites based strain sensors have been widely studied, it is still a challenge to obtain flexible strain sensors with large working range, high sensitivity and reliable stability. In this research, a flexible strain sensor based on poly(styrene-b-ethylene-ran-butylene-b-styrene) (SEBS)/multi-walled carbon nanotubes (MWCNTs) composite fiber was prepared through the wet spinning method. In particular, the effects of MWCNTs content and aspect ratio (L/D) on the morphology, and mechanical, electrical and electromechanical properties of the composite fiber were studied. The results showed that with the increase of MWCNTs content, the tensile strength and elongation at break of the composite fiber decreased, while the electrical conductivity and the strain sensing range increased. For the same MWCNTs content, the composite fiber filled with MWCNTs of the lowest L/D ratio (1.25/15) showed the highest tensile strength and elongation at break; whereas the composite fiber filled with MWCNTs of the highest L/D ratio (20/15) showed the highest electrical conductivity, strain sensing range (0–506%) and sensitivity (gauge factor of 58.274 at 0%–275% strain, and of 197.944 at 275%–506% strain). The fabricated composite fiber could be formed into a knitted fabric and had the ability of detecting various human motions.