Solution to the contact problem of multilayer capacitive dielectric elastomer sensor: laser-engraved elastomer buffer layer

Dielectric elastomers (DEs) are widely used in soft robotics, wearable electronics and advanced sensor technologies due to their ability to withstand large deformations, making them ideal for applications requiring flexible and stretchable components. A key challenge in the field of dielectric elastomer sensors (DESs) is ensuring reliable electrical contact between the electrodes and the external measuring device. Traditionally, contact is established using carbon grease, conductive ink, or copper films, which may suffer from instability under mechanical loading such as compression and stretching. These loads can lead to contact degradation, affecting sensor performance and longevity. A more reliable approach involves the use of wires and conductive threads or fabric, which have been shown to provide enhanced stability under mechanical strain. In this study, we present a novel contact solution utilizing a laser-engraved elastomer buffer layer. This buffer layer, combined with conductive threads and carbon grease, provides enhanced contact fixation, improving durability and adaptability. The laser engraving technique allows for customizable contact designs, enabling optimization based on specific application requirements. This approach offers a promising method for enhancing the reliability of DESs, making them more suitable for dynamic and high-deformation environments.