Micropatterned Composite Hydrogel Sheet with Surface Electronic Conductive Network for Ultrasensitive Strain Sensing

Conductive hydrogels show great promise for wearable sensors but suffer from low sensitivity in small strain ranges. In this study, we developed a micropatterned composite hydrogel sheet (thickness: 1.2 ± 0.1 mm) by constructing a continuous electronic conductive network of carbon nanotubes (CNTs) on a highly crosslinked micropatterned hydrogel sheet. The sheet was fabricated via a two-step synthesis of a polyvinyl alcohol/polyacrylic acid polymer network-crosslinked by Zr⁴⁺ in a glycerol-water system-using sandpaper as the template. The first step ensured tight conformity to the template, while the second step preserved the micropattern's integrity and precision. The reverse sandpaper micropattern enables secure bonding of CNTs to the hydrogel and induces localized stress concentration during stretching. This triggers controllable cracking in the conductive network, allowing the sensor to maintain high sensitivity even in small strain ranges. Consequently, the sensor exhibits ultra-high sensitivity, with gauge factors of 76.1 (0-30% strain) and 203.5 (30-100% strain), alongside a comfortable user experience. It can detect diverse activities, from subtle physiological signals and joint bending to complex hand gestures and athletic postures. Additionally, the micropatterned composite hydrogel sheet also demonstrates self-healing ability, adhesiveness, and conformability, while performing effectively under extreme temperatures and sweaty conditions. This innovative structure and sensing mechanism-leveraging stress concentration and controlled crack formation-provides a strategy for designing wearable electronics with enhanced performance.