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

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.