Stretchable Strain Sensors Based on Deterministic-Contact-Resistance Braided Structures with High Performance and Capability of Continuous Production

Owing to their potential applicability in wearable devices and intelligent robots, stretchable strain sensors have been widely investigated. However, fabricating sensors with high sensitivity, wide sensing range, high repeatability, robustness, and capability for continuous production remains challenging. Herein, a deterministic-contact-resistance braided structure (DCRBS)-based stretchable strain sensor is proposed. The polyester yarns in the sensor tightly trap the silver fibers with the latex thread substrate to form a periodic "Y" structure to avoid slippage of the fibers, thereby facilitating deterministic contact and separation between the silver fibers during cyclic stretching. Owing to this braided structure, the strain sensor exhibits high repeatability (repeatability error = 3.74%), high sensitivity (gauge factor up to 140), wide sensing range (50%), and high robustness (washability, insensitivity to micro-defects). Additionally, the strain sensor can be continuously mass produced using mature raw materials and processing technology. Because of its demonstrated excellent performance, the strain sensor can find applications in human motion monitoring, rehabilitation medicine, and robotic control