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<p>Flexible strain sensors are critical components of emerging wearable electronics, yet simultaneously achieving high sensitivity, broad sensing range, and signal linearity remains a formidable challenge. Herein, we propose a facile and scalable one-step electrospinning strategy, followed by mechanical sintering activation, to fabricate a thermoplastic polyurethane (TPU)/liquid metal (LM)/carbon nanotube (CNT) composite nanofiber strain sensor. This approach constructs a robust solid–liquid bi-continuous network characterized by a unique “Point-Line-Surface” architecture. In this system, CNTs serve a dual function by acting as sensitizers to enhance conductivity and as structural anchors to physically pin the fluidic LM droplets to the TPU matrix. This anchoring effect effectively mitigates the uncontrolled morphological evolution and interfacial slippage of LM domains, thereby suppressing signal hysteresis. Consequently, the sensor exhibits an exceptional combination of performance metrics, including a high gauge factor (GF = 4.3), an ultra-wide sensing range (up to 400%), and superior signal linearity (<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(R^{2} = 0.987\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <msup> <mi>R</mi> <mn>2</mn> </msup> <mo>=</mo> <mn>0.987</mn> </mrow> </math></EquationSource> </InlineEquation>), effectively reconciling the trade-off between sensitivity and linearity. The sensor demonstrates excellent reliability over 2000 cycles and frequency-independent response. Finally, its practical versatility is validated through full-range human health monitoring, ranging from subtle physiological signals to vigorous joint movements. Specific applications include pulse detection, electrocardiogram (ECG) acquisition, and large-scale joint tracking. Furthermore, a smart data glove enabled by the sensor allows for the precise, real-time control of a robotic hand, highlighting its immense potential in advanced human–machine interfaces (HMI).</p>

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One-step fabrication of TPU/LM/CNT nanofiber strain sensors with high linearity and broad range for health monitoring and human–machine interfaces

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Xinlei Cai,
  • Gang Yu,
  • Chenxing Yang,
  • Kedong Bi

摘要

Flexible strain sensors are critical components of emerging wearable electronics, yet simultaneously achieving high sensitivity, broad sensing range, and signal linearity remains a formidable challenge. Herein, we propose a facile and scalable one-step electrospinning strategy, followed by mechanical sintering activation, to fabricate a thermoplastic polyurethane (TPU)/liquid metal (LM)/carbon nanotube (CNT) composite nanofiber strain sensor. This approach constructs a robust solid–liquid bi-continuous network characterized by a unique “Point-Line-Surface” architecture. In this system, CNTs serve a dual function by acting as sensitizers to enhance conductivity and as structural anchors to physically pin the fluidic LM droplets to the TPU matrix. This anchoring effect effectively mitigates the uncontrolled morphological evolution and interfacial slippage of LM domains, thereby suppressing signal hysteresis. Consequently, the sensor exhibits an exceptional combination of performance metrics, including a high gauge factor (GF = 4.3), an ultra-wide sensing range (up to 400%), and superior signal linearity ( \(R^{2} = 0.987\) R 2 = 0.987 ), effectively reconciling the trade-off between sensitivity and linearity. The sensor demonstrates excellent reliability over 2000 cycles and frequency-independent response. Finally, its practical versatility is validated through full-range human health monitoring, ranging from subtle physiological signals to vigorous joint movements. Specific applications include pulse detection, electrocardiogram (ECG) acquisition, and large-scale joint tracking. Furthermore, a smart data glove enabled by the sensor allows for the precise, real-time control of a robotic hand, highlighting its immense potential in advanced human–machine interfaces (HMI).