Preparation of Elastic Macroporous Graphene Aerogel Based on Pickering Emulsion Method and Combination with ETPU for High Performance Piezoresistive Sensors

High-performance pressure sensors provide the necessary conditions for smart shoe applications. In this paper, the elastic Macroporous Graphene Aerogel (MGA) was synthesized via the modified Hummers’ method, and it was further combined with Expanded-Thermoplastic polyurethane (ETPU) particles to assemble MGA-ETPU flexible sensors. The MGA-ETPU has a low apparent density (3.02 mg/cm(3)), high conductivity (0.024 S/cm) and fast response time (50 ms). The MGA-ETPU has a large linear sensing range (0–10 kPa) and consists of two linear regions: the low-pressure region (0 to 8 kPa) and the high-pressure region (8 to 10 kPa), with sensitivities of 0.08 kPa(−1), and 0.246 kPa(−1), respectively. Mechanical test results show that the MGA-ETPU sensor showed 19% reduction in maximum stress after 400 loading–unloading compression cycles at 40% strain. Electrical performance tests showed that the resistance of MGA-ETPU sensor decreased by 12.5% when subjected to sudden compression at 82% strain and returned to its original state within 0.05 s. Compared to existing flexible sensors, the MGA-ETPU sensors offer excellent performance and several distinct advantages, including ease of fabrication, high sensitivity, fast response time, and good flexibility. These remarkable features make them ideally suited as flexible pressure sensors for smart shoes.