Insights from dispersion in carbon nanotubes‐based poly(vinylidene fluoride‐co‐hexafluoropropylene) wearable sensors via solvent casting

Abstract Flexible sensors, made of PVDF‐HFP reinforced with carbon nanotubes (CNTs), are manufactured by solvent casting. More specifically, the effect of evaporation temperature and sonication time is explored. It is seen that two effects govern the dispersion of CNT: the sedimentation half‐time, and the breakage induced by the ultrasonication process. In this regard, it is found that 60°C is an optimum evaporation temperature to reach the highest value of electrical conductivity, since it offers a good balance between these effects, leading to the creation of a more efficient electrical network. This is also confirmed by the AC analysis, where these samples show the highest characteristic frequencies. The electromechanical results show a greater dependency on evaporation temperature for low sonication times, as the breakage induced by an ultrasonic process is not so pronounced and, therefore, the sedimentation effect plays a more dominant role. In addition, cycling tests show robust electromechanical response with cycling, and creep tests prove good electrical response of the sensors, less than 200 ms in some cases. Finally, proof of concept testing of wrist, shoulder, and neck monitoring highlights the potential of the proposed materials for sensing applications. Highlights PVDF‐HFP/CNT nanocomposite strain sensors via solvent casting are proposed. The effect of evaporation temperature and sonication time is studied. DC and AC conductivities were analyzed and modeled via an equivalent circuit. An outstanding Gauge Factor of 86.30 × 10 ⁴ is achieved at 95% of strain level. Two proof‐of‐concepts of medium and large movements are successfully achieved.