Highly Stretchable PPy/PDMS Strain Sensors Fabricated with Multi-Step Oxygen Plasma Treatment

We present highly stretchable polypyrrole (PPy)/polydimethylsiloxane strain sensors of highly improved sensitivity and durability fabricated by a chemical oxidative polymerization with oxygen plasma treatment (O₂ PT). In this study, O₂ PT was performed for 30, 60, and 90 s at each growth stage of the PPy film in three steps to investigate the effects on the sensor performance as well as the microstructural properties of the PPy films. Bonding characteristics with underlying layers and resistance to microcrack generation of the multi-layer PPy films under our given strained state were significantly enhanced by the O₂ PT. The best sensor performance in terms of sensitivity and stability were achieved by PT for 30 s with a maximum gauge factor of ~438 at a uniaxial strain of 50%, excellent durability over 500 stretching/release cycles, and a fast response time of ~50 ms.