Porous piezoresistive sensors offer promising flexible sensing functionality, such as human joint motion detection and gesture identification. Herein, a facile fabrication method is developed using a microwave-based rapid porogen removal technique for the manufacturing of porous nanocomposite sponges consisting of polydimethylsiloxane (PDMS) and well-dispersed carbon nanotubes (CNTs). The porogen amounts and CNT loadings are varied to tailor the porosity and electrical properties of the porous sensors. The sponges are characterized by a scanning electron microscope (SEM) to compare their microstructures, validate the high-quality CNT dispersion, and confirm the successful nanofiller embedding within the elastomeric matrix. Sponges with a 3 wt% CNT loading demonstrate the highest piezoresistive sensitivity. Experimental characterization shows that the sponges with low porosity have long durability and minimal strain rate dependence. Additionally, the developed sponges with 3 wt% CNTs are employed for the human motion detection using piezoresistive method. One experiment includes fingertip compression measurements on a prosthetic hand. Moreover, the sensors are attached to the chest, elbow, and knee of a user to detect breathing, running, walking, joint bending, and throwing motions.

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Nanocomposites consisting of polydimethylsiloxane (PDMS) and well-dispersed carbon nanotubes (CNT) can be cured by microwave radiation within a minute, forming a conductive network within the cured materials. Microwave irradiation delivers energy directly to the inner core of the nanocomposites by heating CNTs and initiating rapid polymerization of the elastomer. In this paper, nanocomposites were fabricated with CNT loadings between 0.5 wt.%–2.5 wt.% via microwave irradiation. Key properties of the nanocomposites including electrical conductivity, microstructures, CNT distribution, density, and surface effects were all characterized. The properties of microwave-cured nanocomposites were compared with those manufactured by the thermal method using a conventional oven. The microwave-curing method substantially increased the electrical conductivity of the nanocomposites due to the improved nanoparticle dispersion and likely CNT alignment. Optimal microwave-curing parameters were identified to further improve the conductivity of the nanocomposites with lowest CNT loading. A conductivity enhancement of 142.8% over thermally cured nanocomposites was achieved for nanocomposites with 1 wt.% CNTs cured via one-step microwave irradiation.

In this paper, polydimethylsiloxane (PDMS) and multi-walled carbon nanotube (MWCNT) nanocomposites with piezoresistive sensing function were fabricated using microwave irradiation. The effects of precuring time on the mechanical and electrical properties of nanocomposites were investigated. The increased viscosity and possible nanofiller re-agglomeration during the precuring process caused decreased microwave absorption, resulting in extended curing times, and decreased porosity and electrical conductivity in the cured nanocomposites. The porosity generated during the microwave-curing process was investigated with a scanning electron microscope (SEM) and density measurements. Increased loadings of MWCNTs resulted in shortened curing times and an increased number of small well-dispersed closed-cell pores. The mechanical properties of the synthesized nanocomposites including stress–strain behaviors and Young’s Modulus were examined. Experimental results demonstrated that the synthesized nanocomposites with 2.5 wt. % MWCNTs achieved the highest piezoresistive sensitivity with an average gauge factor of 7.9 at 10% applied strain. The piezoresistive responses of these nanocomposites were characterized under compressive loads at various maximum strains, loading rates, and under viscoelastic stress relaxation conditions. The 2.5 wt. % nanocomposite was successfully used in an application as a skin-attachable compression sensor for human motion detection including squeezing a golf ball.

Herein, piezoresistive nanocomposite sensors that consist of polydimethylsiloxane (PDMS) elastomer and multiwalled carbon nanotubes (CNTs) are fabricated via the microwave irradiation method. The effects of microwave curing on the materials' electrical, mechanical, and piezoresistive behaviors are investigated by comparing properties with those obtained from the thermal‐cured nanocomposites. Microstructures, porosities, and qualities of CNT dispersion of the manufactured nanocomposites are studied using a scanning electron microscope (SEM). Electrical resistivities of the nanocomposites with various CNT loadings are found to be significantly reduced for microwave‐cured nanocomposites due to the potential improvement of CNT dispersion and enhancement of CNT alignment in comparison with the thermal‐cured nanocomposites. Cyclic compressive tests are performed to determine compressive modulus and piezoresistive properties of the developed nanocomposite sensors. Microwave‐cured sensors demonstrate improved compressibility and similar average gauge factors at strains between 3% and 20% in comparison with the thermal‐cured sensors. The piezoresistive behavior of the microwave‐cured sensors with the lowest CNT concentration is characterized, showing little dependency on strain rate, small drift during an 800‐cycle durability test, and viscoelastic creep response that matches the response seen during an application. The sensors are demonstrated as wearable sensors by detecting human motions including sitting and standing, swaying, and grabbing an object.