High effective sensitivity, wide working range of melt-blown nonwoven conductive substrates for smart wearable strain sensors

Abstract

High sensitivity, wide working range and flexible portability of strain sensors are crucial for smart wearable applications. To obtain these performances, several elastic melt-blown nonwoven substrates with excellent flexibility and high conductivity were developed by loading with polypyrrole through a double-dipping and double-rolling finishing method. The structure and conductivity are characterized by scanning electron microscope, infrared spectrometer, digital source meter and so on. The results indicate that the conductivity of prepared substrates is affected by the pyrrole concentration and polypyrrole amount deposited in nonwovens. Obviously, the conductivity and sensitivity of substrates as strain sensors are highly and positively correlated to the fiber orientation in nonwovens, and the effective working range and corresponding sensitivity of sensors are determined by the elastic deformation interval of melt-blown substrate. When the pyrrole concentration is 5.5%, the nonwoven substrate with 45.30% porosity possesses the anisotropic optimal conductivity with 23.491 S m−1 along winding direction and 15.063 S m−1 along width direction. Moreover, the as-prepared flexible conductive substrate exhibits the characteristics of wide working strain range (0%–24.2%), high sensitivity with 1.94 gauge factor at the range, fast response (0.023 s), tiny hysteresis (0.011 s), high durability and stability after 1000 cycles. Furthermore, the as-prepared sensor provides an effective method to prepare smart wearable strain sensors used as the monitor of finger bending in details and the precise recognition of human voice changes.