Carbon-Based, Ultraelastic, Hierarchically Coated Fiber Strain Sensors with Crack-Controllable Beads

Fiber-based electronics or textronics are spotlighted as a promising strategy to develop stretchable and wearable devices for conformable machine-human interface and ubiquitous healthcare systems. We have prepared a highly sensitive fiber-type strain sensor (maximum gauge factor (GF) = 863) with a broad range of strain (ε < 400%) by introducing a single active layer onto the fiber. In contrast to other metal-based fiber-type electronics, our hierarchical fiber sensors are based on coating carbon-based nanomaterials with responsive microbeads onto elastic fibers. Utilizing the formation of uniform cracks around the microbeads, the device performance was maximized by adjusting the number of microbeads in the carbon-coating layer. We overcoated the carbon-based coating layer of the elastic fiber with a protective polymeric layer and verified no effects on the GF and the range of strain. Our fiber sensors were repeatedly tested more than 5000 times, exhibiting excellent cyclic responses to on/off switching behaviors. For practical applications, the hierarchical fiber sensors were sewed into electrical fabric bands, which are integrable to a wireless transmitter to monitor waveforms of pulsations, respirations, and various postures of level of bending a spinal cord.