Conductive polymer composite-based strain sensors are essential components of flexible wearable devices. However, nonmonotonic responses with shoulder peaks limit their practical application. Herein, we innovatively optimized the shoulder-peak phenomenon in a strain-sensing composite nanofiber filament by regulating carbon nanomaterial dispersion. Further, the preparation methods, characteristics, and performances of the filament strain sensors were systematically introduced. On this basis, transmission electron microscopy, finite element analysis, and mathematic and structural evolution models were used to explore the origin of shoulder peaks and explain the sensing mechanism of conductive networks. Results confirmed that the beacon tower-shaped conductive network designed by constructing nanofiller agglomerates could cause strain concentration and resist the Poisson transverse contraction of nanofibers, considerably improving the monotonicity and sensitivity of the sensor. The strain-sensing performance was optimal when the nanofillers were dispersed using 2.5 wt % of an anionic dispersant. The sensor exhibited a maximum detective strain of 120%, an ultralow detection limit of 0.01%, and high sensitivity and linearity of 9.66 and 0.996 within 20% strain, respectively. Moreover, it showed the advantages of a fast response time (120 ms), excellent durability (3000 cycles), anti-interference, washability, and antibacterial capability. Finally, a smart Kinesio tape was developed for protecting/treating the human body and detecting joint/muscle movement via simple sewing.
Keywords: composite nanofiber filament; flexible strain sensor; nanomaterial dispersion; sensing mechanism; shoulder peak.