Toward flexible piezoresistive strain sensors based on polymer nanocomposites: a review on fundamentals, performance, and applications

The fundamentals, performance, and applications of piezoresistive strain sensors based on polymer nanocomposites are summarized herein. The addition of conductive nanoparticles to a flexible polymer matrix has emerged as a possible alternative to conventional strain gauges, which have limitations in detecting small strain levels and adapting to different surfaces. The evaluation of the properties or performance parameters of strain sensors such as the elongation at break, sensitivity, linearity, hysteresis, transient response, stability, and durability are explained in this review. Moreover, these nanocomposites can be exposed to different environmental conditions throughout their lifetime, including different temperature, humidity or acidity/alkalinity levels, that can affect performance parameters. The development of flexible piezoresistive sensors based on nanocomposites has emerged in recent years for applications related to the biomedical field, smart robotics, and structural health monitoring. However, there are still challenges to overcome in designing high-performance flexible sensors for practical implementation. Overall, this paper provides a comprehensive overview of the current state of research on flexible piezoresistive strain sensors based on polymer nanocomposites, which can be a viable option to address some of the major technological challenges that the future holds.

Recyclable Multifunctional Nanocomposites Based on Carbon Nanotube Reinforced Vitrimers with Shape Memory and Joule Heating Capabilities

The present study focuses on the multifunctional capabilities of carbon nanotube (CNT)-reinforced vitrimers. More specifically, the thermomechanical properties, the Joule effect heating capabilities, the electrical conductivity, the shape memory, and the chemical recycling capacity are explored as a function of the CNT content and the NH2/epoxy ratio. It is observed that the electrical conductivity increases with the CNT content due to a higher number of electrical pathways, while the effect of the NH2/epoxy ratio is not as prevalent. Moreover, the Tg of the material decreases when increasing the NH2/epoxy ratio due to the lower cross-link density, whereas the effect of the CNTs is more complex, in some cases promoting a steric hindrance. The results of Joule heating tests prove the suitability of the proposed materials for resistive heating, reaching average temperatures above 200 °C when applying 100 V for the most electrically conductive samples. Shape memory behavior shows an outstanding shape fixity ratio in every case (around 100%) and a higher shape recovery ratio (95% for the best-tested condition) when decreasing the NH2/epoxy ratio and increasing the CNT content, as both hinder the rearrangement of the dynamic bonds. Finally, the results of the recyclability tests show the ability to regain the nanoreinforcement for their further use. Therefore, from a multifunctional analysis, it can be stated that the proposed materials present promising properties for a wide range of applications, such as Anti-icing and De-icing Systems (ADIS), Joule heating devices for comfort or thermotherapy, or self-deployable structures, among others.

Electromechanical Properties of Smart Vitrimers Reinforced with Carbon Nanotubes for SHM Applications

The Structural Health Monitoring (SHM) capabilities of a well-studied self-healing epoxy resin based on disulfide bonds, through the addition of carbon nanotubes (CNTs), are studied. Since these materials demonstrated, in recent works, a high dependency of the dynamic hardener content on the repair performance, this study aimed to analyze the effect of the vitrimeric chemistry on the electromechanical properties by studying different 2-aminophenyl disulfide (2-AFD) hardener and CNT contents. The electrical conductivity increases with both the CNT and AFD contents, in general. Moreover, an excess of AFD close to the stoichiometric ratio with a low CNT content improved the tensile strength by 45%, while higher AFD contents promoted its detriment by 41% due to a reduced crosslinking density. However, no significant difference in the mechanical properties was observed at a higher CNT content, regardless of the AFD ratio. The developed materials demonstrate a robust electromechanical response at quasi-static conditions. The sensitivity significantly increases at higher AFD ratios, from 0.69 to 2.22 for the 0.2 wt.%. CNT system, which is advantageous due to the enhanced repair performance of these vitrimeric materials with a higher hardener content. These results reveal the potential use of self-healing vitrimers as integrated SHM systems capable of detecting damages and self-repairing autonomously.

Carbon nanoparticle reinforced adhesive films as surface sensors for strain detection

Carbon nanoparticle-reinforced adhesive films have been explored as surface sensors for the detection of small strains. It has been observed that graphene nanoplatelets, GNPs, promote a significant increase of the gauge factor when compared to carbon nanotubes, CNTs (5.6 to 0.6, respectively, at low strains), due to their intrinsic 2D nature. The application as surface sensors for the monitoring of the strain field in an aluminum plate has been proven to be successful, with a repeatable signal under consecutive cycles despite some irreversibility in the first one for GNPs. Furthermore, the electrical response given by the sensors under plastic deformation of the aluminum plate was in total agreement with the mechanical response validated by numerical analysis, proving the high potential of the proposed adhesive film for sensing purposes.

Fe3O4-Nanoparticle-Doped Epoxy Resin as a Detachable Adhesive by Electromagnetic Heating for GFRP Single-Lap Joints

An adhesive based on a Fe₃O₄-nanoparticle (MNP)-doped epoxy resin was proposed for the development of detachable adhesive joints with GFRP substrates. The analysis of cryofractures showed that the increasing MNP content promotes a higher presence of larger aggregates and a lower sedimentation of nanoparticles due to the higher viscosity of the mixture. In this regard, the inclusion of expandable microspheres (MS) induces a more uniform dispersion of MNPs, reducing their sedimentation. The capability of the proposed adhesives for electromagnetic (EM) heating was also evaluated, with increases in temperature of around 100 °C at 750 A, enough to reach the T_g of the polymer required to facilitate the adhesive detachment, which is around 80 °C. Finally, the lap shear strength (LSS) of 14 and 20 wt.% MNP samples was evaluated in a single-lap shear joint with simultaneous EM heating. The LSS values were reduced by 60-80% at 750 A, thus promoting successful adhesive joint detachment under EM heating.

Easy-Scalable Flexible Sensors Made of Carbon Nanotube-Doped Polydimethylsiloxane: Analysis of Manufacturing Conditions and Proof of Concept

Carbon nanotube (CNT) reinforced polydimethylsiloxane (PDMS) easy-scalable sensors for human motion monitoring are proposed. First, the analysis of the dispersion procedure of nanoparticles into the polymer matrix shows that the ultrasonication (US) technique provides a higher electrical sensitivity in comparison to three-roll milling (3RM) due to the higher homogeneity of the CNT distribution induced by the cavitation forces. Furthermore, the gauge factor (GF) calculated from tensile tests decreases with increasing the CNT content, as the interparticle distance between CNTs is reduced and, thus, the contribution of the tunnelling mechanisms diminishes. Therefore, the optimum conditions were set at 0.4 CNT wt.% dispersed by US procedure, providing a GF of approximately 37 for large strains. The electrical response under cycling load was tested at 2%, 5%, and 10% strain level, indicating a high robustness of the developed sensors. Thus, this strain sensor is in a privileged position with respect to the state-of-the-art, considering all the characteristics that this type of sensor must accomplish: high GF, high flexibility, high reproducibility, easy manufacturing, and friendly operation. Finally, a proof-of-concept of human motion monitoring by placing a sensor for elbow and finger movements is carried out. The electrical resistance was found to increase, as expected, with the bending angle and it is totally recovered after stretching, indicating that there is no prevalent damage and highlighting the huge robustness and applicability of the proposed materials as wearable sensors.

Electrical Properties and Strain Sensing Mechanisms in Hybrid Graphene Nanoplatelet/Carbon Nanotube Nanocomposites

Electrical and electromechanical properties of hybrid graphene nanoplatelet (GNP)/carbon nanotube (CNT)-reinforced composites were analyzed under two different sonication conditions. The electrical conductivity increases with increasing nanofiller content, while the optimum sonication time decreases in a low viscosity media. Therefore, for samples with a higher concentration of GNPs, an increase of sonication time of the hybrid GNP/CNT mixture generally leads to an enhancement of the electrical conductivity, up to values of 3 S/m. This means that the optimum sonication process to achieve the best performances is reached in the longest times. Strain sensing tests show a higher prevalence of GNPs at samples with a high GNP/CNT ratio, reaching gauge factors of around 10, with an exponential behavior of electrical resistance with applied strain, whereas samples with lower GNP/CNT ratio have a more linear response owing to a higher prevalence of CNT tunneling transport mechanisms, with gauge factors of around 3-4.

Analysis of strain sensitivity under flexural load of 3D printed carbon nanotube-doped epoxy circuits

A 3D printing system able to print circuits of conductive epoxy resin doped with carbon nanotubes (CNTs) is proposed. Different simple circuits, more specifically lines and strain gauge patterns, made of resins reinforced with 0.3, 0.5, 0.8 and 1 wt% of CNTs were printed on the surface of glass fiber laminates. It was observed that increasing the CNT content reduced the wettability of the printed circuits on the glass fiber substrate. In every case the contact angle was far below 90°. Furthermore, the strain sensing capabilities were analyzed under a flexural load. The results showed that the sensitivity increased with CNT content (with gauge factor values from 1.5 to 2.5) as a result of the prevalent effect of well-dispersed areas due to a reduction in the tunneling distance. On the other hand, the strain gauges showed a lower sensitivity (around 20%-40% less, depending on the condition) compared with line circuits due to localized compressive effects. Furthermore, good repeatability of the strain sensors was proved during cycling tests, with similar baseline and peak values for the electrical resistance in each cycle. Therefore, the proposed materials have a high potential for applications in structural health monitoring.

Mechanical and Crack-Sensing Capabilities of Mode-I Joints with Carbon-Nanotube-Reinforced Adhesive Films under Hydrothermal Aging Conditions

The fracture behavior and crack sensing of mode-I joints with carbon nanotube (CNT)-reinforced adhesive films were explored in this paper under hydrothermal aging conditions. The measured fracture energy of CNT-reinforced joints in grit blasting conditions is higher for non-aged samples than for neat adhesive joints (around 20%) due to the nanofiller toughening and crack bridging effects. However, in the case of brushed surface-treated adherents, a drastic decrease is observed with the addition of CNTs (around 70%) due to the enhanced tribological properties of the nanofillers. Hydrothermal aging has a greater effect in the CNT-reinforced samples, showing a more prevalent plasticization effect, which is confirmed by the R-curves of the specimens. The effects of surface treatment on the crack propagation properties was observed by electrical resistance monitoring, where brushed samples showed a more unstable electrical response, explained by more unstable crack propagation and reflected by sharp increases of the electrical resistance. Aged specimens showed a very uniform increase of electrical resistance due to slower crack propagation, as induced by the plasticization effect of water. Therefore, the proposed adhesive shows a high applicability for crack detection and propagation without decreasing the mechanical properties.

Mechanical and Strain-Sensing Capabilities of Carbon Nanotube Reinforced Composites by Digital Light Processing 3D Printing Technology

Mechanical and strain sensing capabilities of carbon nanotube (CNT) reinforced composites manufactured by digital light processing (DLP) 3D printing technology have been studied. Both CNT content and a post-curing treatment effects have been analyzed. It has been observed that post-curing treatment has a significant influence on mechanical properties, with an increase of Young’s modulus and glass transition temperature whereas their effect in electrical properties is not so important. Furthermore, the strain sensing tests show a linear response of electrical resistance with applied strain, with higher values of sensitivity when decreasing CNT content due to a higher interparticle distance. Moreover, the electrical sensitivity of bending tests is significantly lower than in tensile ones due to the compression subjected face effect. Therefore, the good gauge factor values (around 2–3) and the high linear response proves the applicability of the proposed nanocomposites in structural health monitoring applications.

Novel approach to percolation threshold on electrical conductivity of carbon nanotube reinforced nanocomposites

An analytical model to correlate dispersion state given by waviness, aspect ratio and agglomerate size to the electrical conductivity of CNT nanocomposites is developed.