This
paper presents the design, fabrication, and implementation
of a novel composite film, a polybutadiene-based urethane (PBU)/AgNW/PBU
sensor (PAPS), demonstrating remarkable mechanical stability and precision
in motion detection. The sensor capitalizes on the integration of
Ag nanowire (AgNW) electrodes into a neutral plane, embedded within
a reversibly cross-linkable PBU polymer. The meticulous arrangement
confers pore-free and interfaceless sensor formation, resulting in
an enhanced mechanical robustness, reproducibility, and long-term
reliability. The PBU polymer is subjected to an electrospinning process,
followed by sequential Diels–Alder (DA) and retro-DA reactions
to produce a planarized encapsulation layer. This pioneering technology,
based on electrospinning, allows for more flawless engineering of
the neutral plane as compared to conventional film lamination or layer-by-layer
spin-coating processes. This encapsulation, matching the thickness
of the preformed PBU film, effectively houses the AgNW electrodes.
The PAPS outperforms conventional AgNW/PBU sensors (APS) in terms
of mechanical stability and bending insensitivity. When affixed to
various body parts, the PAPS generates distinctive signal curves,
reflecting the specific body part and degree of motion involved. The
PAPS sensor’s utility is further magnified by the application
of machine learning and deep learning algorithms for signal interpretation.
K-means clustering algorithm authenticated the superior reproducibility
and consistency of the signals derived from the PAPS over the APS.
Deep learning algorithms, including a singular 1D convolutional neural
network (1D CNN), long short-term memory (LSTM) network, and dual-layered
combinations of 1D CNN + LSTM and LSTM + 1D CNN, were deployed for
signal classification. The singular 1D CNN model displayed a classification
accuracy exceeding 98%. The PAPS sensor signifies a pivotal development
in the field of intelligent motion sensors.