Highly Sensitive, Stretchable, and Wash-Durable Strain Sensor Based on Ultrathin Conductive Layer@Polyurethane Yarn for Tiny Motion Monitoring

Strain sensors play an important role in the next generation of artificially intelligent products. However, it is difficult to achieve a good balance between the desirable performance and the easy-to-produce requirement of strain sensors. In this work, we proposed a simple, cost-efficient, and large-area compliant strategy for fabricating highly sensitive strain sensor by coating a polyurethane (PU) yarn with an ultrathin, elastic, and robust conductive polymer composite (CPC) layer consisting of carbon black and natural rubber. This CPC@PU yarn strain sensor exhibited high sensitivity with a gauge factor of 39 and detection limit of 0.1% strain. The elasticity and robustness of the CPC layer endowed the sensor with good reproducibility over 10,000 cycles and excellent wash- and corrosion-resistance. We confirmed the applicability of our strain sensor in monitoring tiny human motions. The results indicated that tiny normal physiological activities (including pronunciation, pulse, expression, swallowing, coughing, etc.) could be monitored using this CPC@PU sensor in real time. In particular, the pronunciation could be well parsed from the recorded delicate speech patterns, and the emotions of laughing and crying could be detected and distinguished using this sensor. Moreover, this CPC@PU strain-sensitive yarn could be woven into textiles to produce functional electronic fabrics. The high sensitivity and washing durability of this CPC@PU yarn strain sensor, together with its low-cost, simplicity, and environmental friendliness in fabrication, open up new opportunities for cost-efficient fabrication of high performance strain sensing devices.