The aim of this study was to develop and optimize a reproducible flexible sensor adapted to thin low-density polyethylene (LDPE) films and/or structures to enable their deformation measurements. As these deformations are suspected to be weak (less than 10%), the developed sensor needs to be particularly sensitive. Moreover, it is of prime importance that sensor integration and usability do not modify the mechanical behavior of its LDPE substrate. The literature review allowed several materials to be investigated and an elastomer/intrinsically conductive polymer PEDOT:PSS (CleviosTM) filled composite was selected to simultaneously combine mechanical properties and electrical conductivity. This composite (made of PEDOT:PSS and silicone Bluesil®) presented satisfying compatibilities with piezoresistive effects, negative temperature performances (in a range from -60 °C to 20 °C), as well as elongation properties (until the elastic limit of the substrate was reached). The method used for creating the sensor is fully described, as are the optimization of the sensor manufacture in terms of used materials, the used amount of materials where the percolation theory aspects must be considered, the adhesion to the substrate, and the manufacturing protocol. Electromechanical characterization was performed to assess the gauge factor (K) of the sensor on its substrate.
Keywords: PEDOT:PSS; flexible piezoresistive sensor; intrinsically conductive polymer; strain gauge.