<p>Knitted flexible sensors, owing to their looped architecture, exhibit excellent stretchability, comfort, and responsiveness, enabling real-time monitoring of biomechanical motion. Here, we systematically investigated the electromechanical performance of conductive fabrics composed of stainless steel, silver-plated, and copper-plated yarns across rib, half-air layer, and air-layer knitting structures. Among them, copper-plated rib fabrics with (35r × 35r)/5 cm density demonstrated superior sensing performance, with stable resistance variation (∼2 to ∼1 kΩ from 0° to 90° wrist bending), high linearity (<i>R</i><sup>2</sup>= 0.959), good stability (<i>δ</i> = 0.232 after 100 cycles), and a gauge factor (GF) of ∼2.73. An equivalent resistance model was established to elucidate the impact of loop geometry on sensor performance, confirming that higher coursewise density lowers resistance and enhances sensitivity. A wearable knitted wristband sensor was fabricated that accurately distinguishes wrist postures. These findings highlight the potential of structured conductive knits as customizable, high-performance platforms for next-generation wearable health monitoring and rehabilitation systems.</p>

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Copper-coated yarn architectures for knitted fabrics with enhanced strain sensitivity and wrist posture recognition

  • Wei Ke,
  • Yixin Liang,
  • Jinchun Liu,
  • Yan Huang,
  • Zhao Li,
  • Ming Yang,
  • Sakil Mahmud

摘要

Knitted flexible sensors, owing to their looped architecture, exhibit excellent stretchability, comfort, and responsiveness, enabling real-time monitoring of biomechanical motion. Here, we systematically investigated the electromechanical performance of conductive fabrics composed of stainless steel, silver-plated, and copper-plated yarns across rib, half-air layer, and air-layer knitting structures. Among them, copper-plated rib fabrics with (35r × 35r)/5 cm density demonstrated superior sensing performance, with stable resistance variation (∼2 to ∼1 kΩ from 0° to 90° wrist bending), high linearity (R2= 0.959), good stability (δ = 0.232 after 100 cycles), and a gauge factor (GF) of ∼2.73. An equivalent resistance model was established to elucidate the impact of loop geometry on sensor performance, confirming that higher coursewise density lowers resistance and enhances sensitivity. A wearable knitted wristband sensor was fabricated that accurately distinguishes wrist postures. These findings highlight the potential of structured conductive knits as customizable, high-performance platforms for next-generation wearable health monitoring and rehabilitation systems.