Mechanically Interlocked Hydrogel-Elastomer Strain Sensor with Robust Interface and Enhanced Water-Retention Capacity

Hydrogels are stretchable ion conductors that can be used as strain sensors by transmitting strain-dependent electrical signals. However, hydrogels are susceptible to dehydration in the air, leading to a loss of flexibility and functions. Here, a simple and general strategy for encapsulating hydrogel with hydrophobic elastomer is proposed to realize excellent water-retention capacity. Elastomers, such as polydimethylsiloxanes (PDMS), whose hydrophobicity and dense crosslinking network can act as a barrier against water evaporation (lost 4.6 wt.% ± 0.57 in 24 h, 28 °C, and ≈30% humidity). To achieve strong adhesion between the hydrogel and elastomer, a porous structured thermoplastic polyurethane (TPU) is used at the hydrogel-elastomer interface to interlock the hydrogel and bond the elastomer simultaneously (the maximum interfacial toughness is over 1200 J/m²). In addition, a PDMS encapsulated ionic hydrogel strain sensor is proposed, demonstrating an excellent water-retention ability, superior mechanical performance, highly linear sensitivity (gauge factor = 2.21, at 100% strain), and robust interface. Various human motions were monitored, proving the effectiveness and practicability of the hydrogel-elastomer hybrid.