Sensitivity Improvement of Stretchable Strain Sensors by the Internal and External Structural Designs for Strain Redistribution

Fiber strain sensors that are directly woven into smart textiles play an important role in wearable systems. These sensors require a high sensitivity to detect the subtle strain in practical applications. However, traditional fiber strain sensors with constant diameters undergo homogeneous strain distribution in the axial direction, thereby limiting the sensitivity improvement. Herein, a novel strategy of internal or external structural design is proposed to significantly improve the sensitivity of fiber strain sensors. The fibers are produced with directional increases in diameter (internal design) or polydimethylsiloxane (PDMS) microbeads attached to surfaces (external design) by combining hollow glass tubes used as templates with PDMS drops. The structural modification of the fiber significantly impacts the sensing performance. After optimizing structural parameters, the highest gauge factor reaches 123.1 in the internal-external structure design at 25% strain. A comprehensive analysis reveals that the desirable scheme is the internal structural design, which features a high sensitivity of 110 with a 100% improvement at ∼5-20% strain. Because of the sufficiently robust interface, even at the 800th cycle, fiber sensors still possessed an excellent stable performance. The morphology evolution mechanism indicates that the resistance increase is closely related with the increased peak width and distance, and the appearance of gaps. Based on the finite element modeling simulation, the quantified effective contributions of different strategies positively correlate with the improved sensitivity. The proposed fiber strain sensors, which are woven into the two-dimensional network structure, exhibit an excellent capability for displacement monitoring and facilitate the traffic control of crossroads.