Towards Tunable Sensitivity of Electrical Property to Strain for Conductive Polymer Composites Based on Thermoplastic Elastomer

The use of conductive polymer composites (CPCs) as strain sensors has been widely investigated and various resistivity-strain sensitivities are desirable for different applications. In this study, the use of mixed carbon fillers and functionalized carbon nanotubes was demonstrated to be vital for preparing thermoplastic polyurethane (TPU)-based strain sensors with tunable sensitivity. To understand the strain sensing behavior, we carried out scanning electron microscopy (SEM), Raman spectroscopy, wide-angle X-ray diffraction (WAXD), mechanical test, and rheology-electrical measurement. Hybrid fillers of multi-walled carbon nanotubes (MWNTs) and carbon black (CB) could reduce the entanglement in conductive network structure, thus increase the resistivity-strain sensitivity. Furthermore, incorporation of additional functionalized MWNTs in the CPCs could enhance the interfacial interaction between nanofillers and TPU, leading to further increase in sensitivity. Through such a simple method, strain sensors could be efficiently fabricated with large strain-sensing capability (strain as large as 200%) and a wide range of strain sensitivity (gauge factor ranging from 5 to 140238). Finally, the exponential revolution of resistive response to strain was fitted with a model based on tunneling theory by Simmons. It was observed that the change in tunneling distance and the number of conductive pathways could be accelerated significantly by adjusting conductive network structure and interfacial interaction. This study provides a guideline for the preparation of high-performance CPC strain sensors with a large range of resistivity-strain sensitivity.