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A rubber-based sensor with over 100 million-level ultra-sensitivity (0-10% strain range) via 3D super-interface.

Xinghuo Wang1, Yaru Huang1, Hui Wang2

  • 1Lab of Advanced Elastomer, South China University of Technology, Tianhe District, Guangzhou, PR China.

Nature Communications
|March 5, 2026
PubMed
Summary

Researchers developed a novel microcrack super-interface flexible sensor (MSFS) using a 3D super-interface strategy. This flexible sensor achieves ultra-sensitivity and a wide strain range, overcoming previous limitations in sensor design.

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Area of Science:

  • Materials Science
  • Nanotechnology
  • Sensor Technology

Background:

  • Flexible sensors face challenges in simultaneously achieving high sensitivity, wide strain range, and linearity.
  • Existing materials and interface designs limit performance, creating an 'impossible triangle' for sensor development.

Purpose of the Study:

  • To develop a flexible sensor with ultra-sensitivity, a wide strain range, and linearity.
  • To overcome the limitations of conventional flexible sensors through a novel interface strategy.

Main Methods:

  • Proposed a 3D super-interface strategy using a patterned rubber substrate and conductive crack layer.
  • Engineered synergistic physical anchoring and hydrogen bonding for strong interlayer bonding.
  • Utilized micro/nano level interactions to create a robust sensor structure.

Main Results:

  • Successfully developed a microcrack super-interface flexible sensor (MSFS) with ultra-sensitivity (0-10% strain, GF 1.1 × 10⁸) and linearity (0.98).
  • Achieved continuous electrical conductivity above 50% strain due to the 3D super-interface.
  • Demonstrated a 22-fold resistance change for a 2% battery expansion, indicating potential for monitoring silicon anode batteries.

Conclusions:

  • The 3D super-interface strategy effectively addresses the limitations of flexible sensors.
  • MSFS exhibits exceptional performance, enabling customized designs for ultra-sensitive applications.
  • The developed sensor shows promise for monitoring expansion in silicon anode batteries.