Effects of Binder and Substrate Materials on the Performance and Reliability of Stretchable Nanocomposite Strain Sensors.

In stretchable strain sensors, highly elastic elastomers such as polydimethylsiloxane (PDMS), Ecoflex, and polyurethane are commonly used for binder materials of the nanocomposite and substrates. However, the viscoelastic nature of the elastomers and the interfacial action between nanofillers and binders influence the critical sensor performances, such as repeatability, response, and hysteresis behavior. In this study, we developed a stretchable nanocomposite strain sensor composed of multiwalled carbon nanotubes and a silicone elastomer binder. The effects of binder and substrate materials on the repeatability, response, hysteresis behavior, and long-term endurance of the strain sensors were systematically investigated using stretching, bending, and repeated cyclic bending tests. Three different binder and substrate materials including PDMS, Ecoflex, and a mixture of PDMS/Ecoflex were tested. The stretchable strain sensors showed an excellent linearity and stretchability of more than 130%. Therefore, the long-term endurance of the strain sensors fabricated with Ecoflex binder should be improved. The strain sensors fabricated with Ecoflex binder showed a relatively large variation in electrical resistance during 10,000-cycle bending tests and repeatability errors at large bending angles. The strain sensors fabricated with PDMS binder showed repeatability errors at small bending angles and a slight response delay of 1 second. On the contrary, the strain sensors fabricated with a mixture of PDMS/Ecoflex binder showed excellent repeatability and response characteristics. The PDMS material showed hysteresis behavior; therefore, the strain sensors fabricated with PDMS binder on PDMS substrate exhibited a large hysteresis behavior in the first stretch-release cycle. It was found that the hysteresis behavior of the strain sensors was mainly dependent on substrate materials than on binder materials. The stretchable strain sensors made of the mixture of PDMS/Ecoflex exhibited excellent repeatability, response, hysteresis behavior, and excellent capability in detecting finger and wrist bending.