Precise Engineering of Conductive Pathway by Frictional Direct-Writing for Ultrasensitive Flexible Strain Sensors

Highly sensitive strain sensors that can detect small strain are in high demand in the fields of displays, robotics, fatigue detection, body monitoring, in vitro diagnostics, and advanced therapies. However, resistive-type sensors that are composed of electrically conductive sensing films coupled with flexible substrates suffer from the limits that their gauge factors (GFs) at small strains (e.g., 0.1-1%) are not high. Herein, through frictional direct-writing of graphite rod on the composite paper substrates, we produced strain sensors with extremely high gauge factor at small strains. The sensors exhibited a gauge factor of 9720 at a small strain of 0.9%, minimum strain detection up to 0.05%, strain resolution of 0.05%, response time of 40 ms, and high stability (>5000 bending-unbending cycles). Compared with the literature results so far, our sensors hold the highest GF value at small strains. Such high sensitivities are due to the precise control of narrow two-dimensional percolative conductive pathway, which means the content of conductive graphite sheets is close to the conductive percolation threshold. The strain sensors have a rapid response to microdeformation changes and can monitor various structural changes, including human motion, through facilitative and effective installation of device designs.