Compatible and Scalable Manufacturing of Piezoresistive Glass Cord Strain Sensors for Rubber Components by Integrating a <scp>1D</scp> / <scp>2D</scp> Nano‐Assembly Conductive Network

ABSTRACT Structural health monitoring (SHM) of polymer composites based on piezoresistive fiber strain sensor (FSS) is a rapidly developing research topic. However, the adoption of structural monitoring of cord‐rubber composites has been inhibited by the difficulty of introducing conductive fillers onto the commercially available glass cord surface without reducing the bond strength in the adhesive layer that connects the rubber to the glass. In addition, there are issues related to the sensitivity and reliability of SHM. In this study, glass cords coated with nanofiller/resorcinol formaldehyde latex (RFL) nanocomposites were successfully prepared via a layer‐by‐layer (LBL) dip coating, with surface coatings consisting of carbon nanotubes (CNTs), graphene nanosheets (GNPs), and LBL assembly networks. Cords coated with the LBL conductive network exhibited excellent piezoresistive linearity, enhanced sensing sensitivity (an average gauge factor of 14.9), and improved sensing stability with a decay ratio ( D / P ) of 51.3% at an applied strain range of 0.5%–1.0%. This originated from the reversibility of nano‐assembly network structural change under cyclic loading. The proposed fabrication process is simple, efficient, and promising to scale up, making it compatible with the current cord production methods. This study provides an essential guide in the manufacture of a self‐sensing glass cord that not only promotes cord/rubber bonding but also functions as an interfacial damage sensor to integrate SHM capability into conventional cord‐rubber composites for future applications.