Polyurea–Kevlar-Protected Capacitive Pressure Sensor with a Porous Dielectric Layer for Pressure Monitoring in Extreme Environments

Flexible pressure sensors have attracted significant attention due to their broad application potential in areas such as health monitoring, human–machine interfaces, and structural health diagnostics. However, their practical use in extreme environments is often hindered by challenges, including mechanical impact, environmental degradation, and limited long-term stability. In this study, we developed a highly reliable and robust capacitive pressure sensor by engineering a flexible dielectric layer with a porous structure via a template-removal technique. This layer was further integrated with a protective architecture composed of a polyurea elastomer and fiber fabric. The resulting pressure sensor demonstrated a wide detection range and a high sensitivity. Rigorous drop-weight impact tests and pressure cycling experiments confirmed their outstanding impact resistance and long-term operational durability. Additionally, the sensor consistently maintained its performance under harsh environmental conditions such as salt spray, high humidity, ultraviolet exposure, and extreme temperatures, highlighting its exceptional robustness. The sensor’s capability for pressure distribution monitoring was further validated through the design and implementation of a pressure sensor array. With its superior reliability, mechanical durability, and environmental resilience, this sensor presents a robust solution for pressure monitoring in complex environments, making it an excellent candidate for applications, including battery monitoring in energy vehicles, industrial equipment inspection, and structural health monitoring.