Patterned Metal Flexible Films as a Strain Sensor with Good Durability and Anti-Corrosion Property

Area of Science:

• Materials Science
• Electrical Engineering
• Corrosion Science

Background:

• Corrosion and electrical failure are significant challenges for sensors in humid environments and under load.
• Flexible strain sensors require robust designs to ensure long-term performance and reliability.
• Existing sensors often lack the necessary durability and environmental resistance for demanding applications.

Purpose of the Study:

• To develop a highly durable, corrosion-resistant flexible strain sensor.
• To investigate the impact of film dimensions and temperature on sensor conductivity.
• To evaluate the sensor's performance in real-time micro-strain detection.

Main Methods:

• Fabrication of a flexible strain sensor using a patterned sandwich structure.
• Coating the sensor with Polydimethylsiloxane (PDMS) for environmental protection.
• Testing sensor durability through multiple tensile cycles and large deformations.
• Evaluating electrical conductivity changes under varying film dimensions and ambient temperatures.
• Assessing the sensor's performance in humid environments and during steel plate tensile tests.

Main Results:

• The sensor demonstrated exceptional durability and stability after repeated large deformations.
• The PDMS coating effectively shielded the conductive layer from corrosive humid environments.
• High linearity and sensitivity were observed between resistance change and strain in tensile tests.
• The sensor maintained stable performance, efficiently blocking corrosive effects.

Conclusions:

• The developed patterned flexible strain sensor exhibits excellent durability and corrosion resistance.
• The sensor design effectively prevents electrical failure in humid conditions and under load.
• Significant potential exists for this sensor in applications requiring reliable strain monitoring in harsh environments.