Practical and Durable Flexible Strain Sensors Based on Conductive Carbon Black and Silicone Blends for Large Scale Motion Monitoring Applications

Presented is a flexible capacitive strain sensor, based on the low cost materials silicone (PDMS) and carbon black (CB), that was fabricated by casting and curing of successive silicone layers—a central PDMS dielectric layer bounded by PDMS/CB blend electrodes and packaged by exterior PDMS films. It was effectively characterized for large flexion-angle motion wearable applications, with strain sensing properties assessed over large strains (50%) and variations in temperature and humidity. Additionally, suitability for monitoring large tissue deformation was established by integration with an in vitro digestive model. The capacitive gauge factor was approximately constant at 0.86 over these conditions for the linear strain range (3 to 47%). Durability was established from consistent relative capacitance changes over 10,000 strain cycles, with varying strain frequency and elongation up to 50%. Wearability and high flexion angle human motion detection were demonstrated by integration with an elbow band, with clear detection of motion ranges up 90°. The device’s simple structure and fabrication method, low-cost materials and robust performance, offer promise for expanding the availability of wearable sensor systems.