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Figure 1. Applications of piezoresistive polymer nanocomposites based on carbon nanostructures. a) Highly twistable tactile sensing array made from
polydimethylsiloxane (PDMS) and carbon black nanoparticles.[23] (Reprinted from ref. [23], with permission from Elsevier), b) stretchable singlewall CNT/PDMS
strain sensor for human motion detection.[20] (Reprinted from ref. [20], with permission from Nature Publishing Group), c) Organic light-emitting diode on a
graphene/polymethyl methacrylate (PMMA) transparent conducting electrode.[24] (Reprinted from ref. [24], with permission from Nature Publishing Group), d)
schematic showing the use of carbon nanotubes in a polymer matrix to self-sense crack propagation and damage in advanced multiscale composites.
evidences that the full piezoresistivity of the carbon nanotube is that upon sufficient energetic excitation (voltage, temperature)
not transferred to its polymer nanocomposite. This is partly the electrons can tunnel or hop over small distances crossing a
because the applied strain is not fully transferred to the filler.[25] thin polymeric layer; this (quantum) tunneling resistance
Therefore, in this kind of nanocomposites, the inherent depends on the interparticle distance in an exponential
piezoresistivity of the carbon fillers and the change in their fashion.[43–45] The maximum tunneling distance in polymers
dimensions upon loading provide only a small contribution to filled with carbon nanostructures varies depending on the
the measured piezoresistivity.[25,37] nanostructure and polymer type; the maximum tunneling
In polymer composites at relatively low filler contents, distance has been theoretical suggested to be close to
piezoresistivity is driven by the change in the filler network 2 nm,[40,44,46] although some other studies have considered
configuration upon mechanical loading. The major underlying slightly higher tunneling distances (5 nm).[45]
mechanisms which govern the change in electrical resistance The relative influence of these mechanisms driving the
upon loading are schematically represented in Figure 3. They effective measured piezoresistivity in a polymer composite
can be grouped into three main aspects which occur upon strain depends on several factors related to the filler itself, to the
application, viz. reconstruction of the conductive network polymer matrix, and to their interaction and state of dispersion.
(creation and destruction of conductive pathways), changes in Several numerical and analytical modeling efforts have advanced
the contact resistance between conductive fillers, and changes towards understanding the piezoresistive effect in polymer
in the filler-to-filler interparticle distance.[38–42] As depicted in composites, including effects such as tunneling, CNT-to-CNT
Figure 3, upon straining the composite new conductive pathways contact, CNT morphology and waviness, agglomeration, inher-
can be created and others destroyed; the filler-to-filler contact ent CNT piezoresistivity and loading conditions.[37,41,45,47–54]
resistance also changes upon strain application, since the filler- From the materials viewpoint, the geometry of the filler and its
to-filler contact area and the number of contact points also dispersion within the matrix, the mechanical and rheological
changes. There is also a very important non-contact scenario, properties of the polymer matrix, as well as its electrical
which is governed by the interparticle distance. It is accepted permittivity are among the most influential factors.[54–57]
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Figure 4. Schematic representation of the concept of excluded volume (area) in a 2D On the other extreme, considering large
projection. a) 25 identical solid circles covering a squared area, b) 5 cylinders (whose total graphenic sheets with Lr ¼ dd (a few microns,
area approximately equals that of the 25 circles) covering the same squared area. i.e., microsheets) yields,
V rExc 4 dr
¼ ð3bÞ
V dExc π dd
V rExc 3 Lr 2
¼ ð2aÞ
V sExc 4 ds
For CNT lengths in the order of microns and diameters in the
order of tens of nanometers Equation (3a) is much higher than 1,
! while Equation (3b) is significantly lower than 1. This means that
V rExc 4 L2r dr the excluded volume of graphene and few layer graphene sheets
¼ ð2bÞ
V dExc π d3d can be less or more than that of CNTs depending on the
proportion between the lateral dimension of the sheets and the
The comparison between the excluded volume of CNTs and that CNT length.
of spherical carbon nanoparticles such as carbon black nano- A high excluded volume means that the network of fillers
particles or fullerenes can be done in a straightforward manner within the composite has many spaces among the fillers, that is,
using Equation (2a). Since the diameter of a carbon nanoparticle that the network is loosely packed (see Figure 4b). This means
(say ds 20 nm) is typically about 2 orders of magnitude smaller that the number of conductive paths is small and as such, small
than the “typical” length of a CNT (say Lr ¼ 2 μm), Equation (2a) changes in the network configuration (upon strain application)
implies that the excluded volume of carbon nanotubes is about 4 are expected to produce large changes in electrical resistance, as
orders of magnitude higher than that of spherical carbon explained in connection with Figure 2. Thus, a high excluded
nanoparticles. A schematic of this is depicted in Figure 4 in a volume is expected to promote high piezoresistive sensitivity,
bi-dimensional (2D) projection, where the total area covered by the and this may be the reason why higher piezoresistive sensitivity
25 (black) solid circles (2D projection of spheres) is approximately has been found for composites with CNTs as fillers, as compared
equal to the total area covered by the 5 elongated entities (2D to another fillers such as spherical carbon particles or flakes of
projection of cylinders); that is, Figure 4a and b have the same area smaller lateral dimensions at the same weight fraction.[67] It
fraction of solid fillers. As seen from Figure 4a, there is still room to should be kept in mind, however, that the number of filler-
fit more identical circles among the existent solid ones (these to-filler contact points within the conductive network is also a
spaces are represented as empty circles with dashed lines, to strong factor which influences the electrical conductivity and
pictorially prove the point) so the excluded area (dashed red spaces) piezoresistivity of this kind of nanocomposites. It is speculated
is very small in this case; however for the case of cylinders that a relative high number of contact points should yield
(Figure 4b), assuming that interpenetration is not allowed, there is higher piezoresistive sensitivity, because of the higher changes
plenty of free area that cannot be interpenetrated by another in contact resistance produced upon straining the composite.
cylindrical entity of the same dimensions, since it does not fit the Precise calculations of the number of contact points within a
space available, that is, there is significantly more excluded area. network requires specialized statistical calculations, such as
Notice also that, at the same area fraction, the solid circles of those based on molecular dynamics, Montecarlo methods, or
Figure 4a do not form a single percolated path, while at least a other statistical tools.[63,68] According to Wouterse et al.[68] the
vertical contacting path can be found among the solid cylindrical contact number for uncorrelated elongated spherocylinders
entities of Figure 4b. This is an important geometrical aspect depends on several factors such as the filler concentration and
which explains the significantly lower percolation thresholds aspect ratio. According to these authors, above a critical filler
achieved for elongated cylinders (carbon nanotubes) compared to concentration, the contact number for rods increases with
spherical particles (e.g., carbon black).[60,65,66] increased filler volume fraction. They also found that the effect
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of the aspect ratio is nonmonotonic, with the contact number compression or bending). The main features of the piezoresistive
first increasing for aspect ratios less than six and then decreasing response of the material are captured in Table A1 by four
for elongated spherocylinders with aspect ratios above six. For parameters, referring to its linear (L) or nonlinear (NL) character,
aspects ratios above 80 the contact number is weakly maximum strain sensing capability (emax), extend of linear
dependent on the aspect ratio but below this aspect ratio the piezoresistivity (eL), and piezoresistive sensitivity (GF). The
dependence is significant. Thus, a compromise may exist difference between eL and emax provides an indication of nonlinear
between the density of contact points within the conductive piezoresistivity.
network, the excluded volume and the filler concentration. It is Carbon black (a black powder produced by the incomplete
also important to bear in mind that the perspective of excluded combustion of carbonaceous or petroleum products) is likely the
volume and number of contact points covers only the earliest carbon filler that has been extensively used to produce
morphological and statistical packing aspects between fillers, electro-conductive polymer composites with strain sensing
and many other aspects such as the rheology of the polymer and capabilities. In Figure 5, summary plots of the piezoresistive
its dielectric properties, the waviness of the filler, the filler sensitivity (GF) of CB/polymer (Figure 5a) and graphite/polymer
functional groups and filler/matrix interface (which impacts composites (Figure 5b) are presented (data extracted from
strain transfer), alignment and dispersion, and the level of strain Table A1). An immediate observation form this table is that, in
attained need also to be taken into account when analyzing the comparison to other carbon nanostructures such as carbon
piezoresistive response of a carbon filled polymer composite. nanotubes or graphenic flakes, the concentration of CB used
Finally, it should be pointed out that not all changes in the for piezoresistive applications is notoriously higher. This is a
effective electrical resistance of a composite should be named geometrical aspect, since higher filler concentrations are needed
piezoresistivity. The key issue in piezoresistivity is that the to reach electrical percolation for spherical particles than for
changes in electrical resistance are driven by changes in strain nanostructures of high aspect ratio, see Figure 4. As seen from
(or stress/pressure) in the material. Many other aspects that Figure 5a, for CB, ES matrices have been more explored than TS
occur in advanced polymer composites such as matrix and TP polymers. It is also noticed that the CB concentration of
cracking,[31] delamination,[69] or even moisture or temperature TS and TP composites is generally below 15 wt%, while higher
variations[70] may also yield changes in the effective electrical concentrations (>30 wt%) are used for ES matrices.
resistance of the composite, but those phenomena (albeit In general, the piezoresistive response of CB/polymer
interesting) should not be termed piezoresistivity. This is composites is nonlinear, see Table A1. Gage factors are
because in those cases the change in electrical resistance is not customary extracted from the initial part of the piezoresistive
directly triggered by changes in strain or stress, but by other curve (i.e., e < 5%), where an approximately linear behavior is
physical parameter. observed. The ultimate strain of composites with TS matrices is
usually low ( < 6%), while TP and ES composites can sustain
larger strains. The majority of the piezoresistive works report
3. Polymer Composites Filled with Graphite uniaxial tension loading, see Table A1, and the majority of the GF
and Carbon Black reported range between 3 and 15, see Figure 5a. Negative
piezoresistivity has also been observed under tension and
This section covers past and present work on the piezoresistive compression.[38] especially for elastomeric composites. Negative
behavior of polymer composites filled with two of the earliest piezoresistivity means that, under uniaxial tensile loading (e>0),
carbon allotropes investigated to this aim, viz. carbon black (CB) the electrical resistance decreases (ΔR < 0), or that ΔR increases
and graphite. A review of the most relevant results, trends, and under compression. For TS composites, the family of CB/epoxy
findings regarding the piezoresistive response, strain, and under tensile loading is the most investigated one, with ultimate
damage sensing of these composites is presented in this section. strains below 6% because of the brittleness of epoxy in
The inclusion of these two fillers to
thermosettings, thermoplastics, and
elastomers are discussed as a function
of their distinctive piezoresistive re-
sponse. Furthermore, strain and pres-
sure sensing work ranges are identified,
and a summary of the piezoresistive
sensitivity (GF) for different polymer
composites is discussed. A literature
survey summarizing the piezoresistive
behavior of polymer composites filled
with CB and graphite is included in
Table A1 of Appendix A. Such a table
is organized by filler type and includes
thermosetting (TS), thermoplastic (TP)
and elastomeric (ES) matrices, as well
as the corresponding filler concentra- Figure 5. Summary of published gage factors for CB and graphite polymer composites. a) CB/polymer
tion (wt%) and loading type (tension, composites, b) graphite/polymer composites. Data extracted from Table A1.
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tension.[71,72] The piezoresistivity of CB/TP composites has also mechanisms support positive piezoresistivity, while the latter
been investigated,[73–78] finding positive GFs between 3 and 30, one explains negative piezoresistivity.
see Figure 5a. Zhao et al.[74] evaluated the tensile piezoresistive Several authors have also explored the piezoresistive behavior
behavior of a 13 wt% CB/polypropylene composite and of CB/polymer composites under cycling loading,[8,38,72,74–
77,85,90]
reported a nonlinear increasing piezoresistive behavior. The viscoelastic relaxation,[87] and creep,[73,84] and a few of
authors argument that both, formation and breakdown of them have pointed out the effect of hysteresis.[72,74,75,77,90]
conductive paths, compete during the loading process, making Damage and irreversible phenomena can also be assessed by
the curve nonlinear. As seen from Table A1, CB/ES composites means of the electrical response of the composite. In this regard,
made from rubber or polyisoprene are among the most common CB/HDPE composite films under uniaxial tension have shown
composites which have been investigated using CB.[73,79–85] negligible variations in R for e < 8% (elastic region, according
Styrene ethylene butylene styrene (SEBS), a thermoplastic to the authors), and a sudden increase of R for higher strains
elastomer, has also been filled with CB presenting large corresponding to the elastic-to-plastic transition.[76] The authors
deformation capabilities and piezoresistive strain sensing.[86,87] state that this unique electrical property could be used to identify
Elastomers are by far the most explored polymer matrices for CB the elastic and plastic regions, representing a valuable tool for
likely because of their large stretch ratio, high flexibility, and damage assessing.
interest of the rubber industry. However, they are also more Regarding the use of graphite as a filler material, the
prone to present time-dependent viscoelastic relaxation and piezoresistive behavior of graphite/polymer composites
creep, which is captured by the piezoresistive response.[87,88] For under tension,[91] compression,[6,92–94] and bending[95,96] has
elastomeric composites under tension, most of the reviewed also been investigated. Figure 5b summarizes the GFs of
literature (Table A1) shows an increase of electrical resistance graphite/polymer composites for different polymer matrices.
with increased strain, that is, positive piezoresistivity, following a In comparison to CB/polymer composites, evaluation of the
nonlinear behavior, especially at high strains (above 20%). When piezoresistivity of graphite/polymer composites in terms of
the composite is stretched, CB agglomerates are pulled away, strain or GFs has been less explored. A great number of the
disrupting certain conducting paths, with the concomitant existent works report on sensitivity as a function of applied
increase in R. According to Figure 5, the GFs (extracted from pressure, that is, calibrating as a pressure sensor. According to
e < eL, which ranges from 4% to 17% depending on the material) our literature survey (see Table A1 and Figure 5b), the great
for CB/ES composites have been reported above 12. A different majority of graphite/polymer composites exhibit positive
piezoresistive behavior under tension has been observed by piezoresistivity with the majority of GFs ranging from 7 to
other authors such as Flandin et al.[8,38] for an ethylene-octene 25. From the literature survey conducted, Shevchenko et al.
elastomer filled with CB. These authors reported that, under reported the highest GFs for graphite/polymer composites using
tensile loading, after the increase in R during the first stages of a polypropylene (PP) matrix under tension, with GFs associated
strain (elastic region) a decrease in R (negative piezoresistivity) to the linear region of the piezoresistive plots (e < 1%) ranging
occurs at higher tensile strains. The authors claim that for the from 7 (45 wt%) to 100 (12.5 wt%).[91] These authors also
ethylene-octene (comprising flexible chains with fringed micel- presented evidence that the linearity of the graphite/PP
lar crystals), the large strains produce new conducting pathways piezoresistive curves increases as the graphite volume fraction
or improves the existent ones by CB reorientation and/or strain- increases. Serra et al.[96] reported on the piezoresistive behavior
driven agglomerate breakdown. Both positive and negative GFs of graphite/epoxy composites under bending. The composites
have also been reported in different works under compression, were bonded to a rigid substrate (alumina or aluminum) which
see Figure 5a. Negative GFs, that is, increase of R with increased
compressive strain, have been explained in terms of the
destruction of the conductive network under compression,[84,85]
while positive GFs have been explained in terms of increased
particle volume fraction in the composites due to volume
reduction during compression.[73] Wang et al.[89] explored CB/
silicone rubber composites at CB-to-rubber mass ratios varying
from 0.08:1 to 0.24:1 (7.4 to 19.4 wt%). These authors report both
positive and negative piezoresistivity for the same specimen
at different levels of strain, and also depending on the CB
concentration, see Figure 6. For example, for CB concentrations
above 11.5 wt% they found positive piezoresistivity for all strain/
stress levels tested, but between 9.1 wt% and 10.7 wt% they
found both, positive and negative piezoresistivity, see Figure 6.
For concentrations of 8.3 wt% and below, however, the
piezoresistive behavior turned monotonically negative, see
Figure 6. This complex behavior was explained in terms of
three main effects caused by the translation and rotation of the
CB particles due to compression, viz. reduction of the gap Figure 6. Piezoresistive response of CB/rubber composites for different
between conductive paths, formation of new conducting paths, CB loadings.[89] (Reproduced from ref.[89], with permission from
and destruction of existing conductive paths. The first two Elsevier).
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Table 1. Summary of pressure-dependent piezoresistive behavior of polymer composites filled with CB and graphite.
Pressure-dependent piezoresistivity
Filler wt% Matrix L/NL Pmax (kPa) PL (kPa) S (x103, kPa1) Ref.
[99]
Carbon black 20 Natural rubber NL 2400 1600 0.4
[100]
10.3 PMVS L 1200 1200 0.07
10 Silicon rubber NL 600 80 1.35 to 1.65 [101]
[89]
0.16 Silicon rubber NL 1000 500 0.5
10 Polyisoprene NL 400 40 0.5 [104]
[106]
Graphite 0.5 Epoxy NL 75 000 13 000 0.05
20 HDPE NL 25 000 5000 0.04 to 0.08 [107]
[106]
3 Silicon rubber NL 750 200 1.3
6.6 Silicon rubber NL 500 100 0.3 [108]
[108]
22.1 Silicon rubber NL 500 100 1.2
[98]
30 Polyurethane NL 60 5 63
Acronyms: HDPE ¼ High density polyethylene, PMVS ¼ poly(methylvinylsilioxane), L ¼ Linear, NL ¼ Nonlinear, Pmax ¼ Maximum pressure registered by the electrical
signal, PL ¼ Maximum pressure corresponding to approximately linear piezoresistivity, S ¼ Pressure-dependent piezoresistive sensitivity.
was directly bent. Authors found that the GF of graphite/epoxy as the number of cycles increases. These authors also
composites bonded to a beam decreases with increased graphite highlighted the dependence of the piezoresistive response on
concentration for both alumina and aluminum substrates. the creep behavior of the polymeric matrix and the elastic
Using a similar bending approach, Frazier and Allen[95] reported properties of the fillers.[6] Other authors such as Chen et al.[94]
the piezoresistive behavior of graphite/polyimide composites have also reported that the hysteresis reduces with increased
bonded to a rigid silicon substrate. These authors found that the number of cycles for graphite nanosheets in silicone rubber.
GF of the composites first increases with increased graphite For pressure sensors, the piezoresistive behavior of CB-based
concentration, and then decreases, reporting a peak GF of 16.8. It and graphite-based polymer composites can also be approached
is important to notice that when the piezoresistive material is in terms of applied pressure (instead of applied strain). To
not directly stretched but bonded to a beam, the stress/strain quantify the linear piezoresistive sensitivity as a function of
transfer from the tested beam (substrate) may not be perfect,
which would affect the piezoresistive measurement and
determination of gage factor. On the other hand, Beruto
et al.[93] reported that R decreases with increased compressive
strain (i.e., positive piezoresistivity) for graphite/rubber compo-
sites, being such changes more significant as the graphite
concentration decreases and approaches the percolation thresh-
old. Chen et al.[94] reported a negative piezoresistivity for a
graphite nanosheet/rubber composite under compression,
which is also more pronounced as the graphite concentration
is closer to the percolation threshold. The authors argument that
the mechanism underlying such a negative piezoresistivity is
the breakdown of conductive pathways and that the transport
mechanism can be understood in terms of the tunneling
conduction between conducting particles. Cyclic load-
ing[6,91,94,96] and relaxation tests[92,96] have also been explored
by a few authors. Regarding irreversible effects, Shevchenko
et al.[91] showed that the piezoresistive hysteresis under loading-
unloading cycles is reduced with increased number of cycles and
by increasing the particle concentration. Lu et al.[6] also reported
that the piezoresistive response is different among sequential Figure 7. Summary of published gage factors for SWCNT and MWCNT
loading-unloading cycles, being more stable (but less sensitive) polymer composites. Data extracted from Table A1.
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the applied pressure (P), a pressure-dependent piezoresistive more economical to synthesize in large scale. Notice that the
coefficient S ¼ (ΔR/R0)/ΔP has been customarily used.[97,98] magnitude of the GFs for SWCNT and MWCNT composites in
This coefficient is the pressure analogous of the GF, which is Figure 7 are comparable to those obtained using graphite or
defined in terms of pressure instead of normalized strain. carbon black in Figure 5, but as seen from Table A1, those for
Table 1 summarizes the most relevant pressure-dependent graphite and carbon black require significantly higher filler
piezoresistive parameters for several CB and graphite polymer concentration. Reports on negative gage factors are scarce, but
composites. Relatively high filler loadings, usually above 5 wt%, they have also been reported, especially under compressive
are generally used for these applications, although composites loading.[112] Particular features of CNT polymer composites with
with lower concentrations (<1 wt%) can also be found, see TS, TP, and ES matrices are discussed in the following sections.
Table 1.
Higher loadings of CB and graphite, as compared to other
fillers such as carbon nanotubes or graphenic flakes, are 4.1. Thermosetting Matrices
required for pressure sensing applications of these materials due
to the corresponding lower excluded volume and aspect ratio of Epoxy thermosettings filled with SWCNTs[113] and
these fillers. Elastomeric matrices are undoubtedly the most MWCNTs[48,71,72,110,114–117] are among the most extensively
used ones for pressure sensors due to their suitable flexibility investigated polymers regarding piezoresistivity of polymer
and mechanical properties. The applied pressures customarily composites, compared to other thermosetting polymers such as
range from few tents of KPa to nearly 100 MPa. Except for the vinyl ester[112] or polyester. Given their low processing viscosity, a
high value (63 103 kPa1) reported by He et al.,[98] the distinctive feature of these polymer composites is their capability
magnitude of the reported sensitivity factors in Table 1 ranges of reaching electrical percolation at CNT concentration levels
from 0.04 103 to 3 103 kPa1. Positive and negative significantly smaller than those for thermoplastics or elasto-
pressure-dependent piezoresistivity has also been observed. mers, see Table A1. Because of these, CNT concentrations of
0.3 wt% or below are sufficient to guarantee piezoresistivity in
thermosetting composites (see Table A1). This very low filler
4. Polymer Composites Filled with Carbon concentration, alongside with the superior mechanical proper-
Nanotubes ties of thermosetting composites, makes them particularly
attractive for further developments of advanced multiscale
Among the carbon-filled polymer composites, those modified hierarchical composites loaded in tension, compression, or
with CNTs are undoubtedly the ones that have captured more bending.[31,118–120]
attention of the scientific community, as evidenced by the Linear piezoresistivity is quite common for CNT thermoset-
numerous publications to date. They range from the early work ting composites loaded in tension with low ultimate strains
on buckypaper of Dharap et al. in 2004[109] to current and (Figure 8a), but nonlinear and even nonmonotonic piezoresis-
ongoing research.[110,111] A brief literature survey summarizing tivity may also occur for thermosettings or modified thermoset-
the piezoresistive behavior of polymer composites filled with tings with relatively “high” (within the context of
SWCNTs and MWCNTs is included in Table A1 of Appendix A. thermosettings) ultimate strains.[71] For this later case, an
Such a table is organized by filler and matrix types and includes inversion of the piezoresistive trend (from positive to negative)
the corresponding filler concentration (wt%) and loading type, as may occur for certain CNT weight concentrations under
discussed in section 3. relatively large deformations (Figure 8b, see ref. [71]), presum-
The literature survey suggests that the majority of published ably because of polymer inelastic behavior. Negative piezor-
works are on epoxy composites filled with MWCNTs, and esistivity means that the effective (three-dimensional) distance
substantial work has also been published using a variety of between CNTs is reduced as the polymer is axially stretched,
thermoplastic and elastomeric matrices such
as thermoplastic-polyurethanes (TPUs) and
polydimethylsiloxane (PDMS). By far, the
great majority of the piezoresistive works
report only tensile loading, being compres-
sion and flexural loading significantly less
reported.
Figure 7 summarizes the piezoresistive
sensitivity (in the form of gage factors) of the
SWCNT and MWCNT polymer composites
listed in Table A1. Data for buckypapers (BP) is
also included for completeness. As seen from
this figure, the great majority of GFs for CNT
polymer composites are found between 1 and
7, without a particularly distinctive trend Figure 8. Piezoresistive response of thermosetting polymer composites. a) Linear response of
between SWCNTs and MWCNTs. However, a 0.3 wt% MWCNT/vinyl ester composite.[121] (Reproduced from ref. [121], with permission from
composites with MWCNTs seem to be more Elsevier), b) nonlinear and nonmonotonic response of a 0.1 wt% MWCNT/epoxy composite.[71]
reported, probably because they are easier and (Reproduced from ref. [71], with permission from the American Physical Society).
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and may be caused by matrix plasticity, lateral CNT motion by of the effective resistance and capacitance that determine the
Poisson’s effect and/or three-dimensional CNT network rear- overall electrical response of the material.[110]
rangement under large strains.[71,111]
The CNT weight concentration also affects the piezoresistive
response, and is commonly accepted that lower CNT concen- 4.2. Thermoplastic Matrices
trations yields higher piezoresistive sensitivities.[112,114] This is
because lower CNT concentrations yields less redundant paths Thermoplastics are generally tougher and more deformable than
forming the CNT network, and also the tunneling effect is thermosetting polymers; therefore, piezoresistivity has been
expected to be more significant for CNT concentrations close to extended to larger strain sensing capabilities for CNTcomposites
percolation.[53] using thermoplastic matrices (see emax listed in Table A1 of
Tensile loading is by far the most commonly investigated appendix A). As seen from Table A1, a large variety of
loading case, although a few works have also investigated thermoplastic polymers such as polymethyl methacrylate
compression[112,121] and bending.[110] Ku-Herrera and Aviles[121] (PMMA),[32,122] polyvinylidene fluoride (PVDF),[123–127] polycar-
used 25.4 mm long prisms of 12.5 mm square cross section to bonate (PC),[128] polyethylene oxide (PEO),[129] polysulfone
investigate the piezoresistive response and damage accumula- (PSF)[130] polyethylene terephthalate (PET),[131] and polypropyl-
tion of 0.3 wt% MWCNT/vinyl ester specimens under uniaxial ene (PP)[33,74] have been modified with CNTs to achieve
compression loading. They found a nonlinear and nonmono- piezoresistive strain sensing capabilities. In general, the gage
tonic behavior under monotonic compression loading up to factors reported for CNT/thermoplastic composites in the elastic
failure (see Figure 9a), with the electrical resistance first regime are similar (or slightly above) than those for thermoset-
decreasing (positive gage factor) and then increasing (negative tings, as pointed out in Figure 7. However, because of their larger
gage factor) for relative large strains (e>2.5%). The transition deformation capabilities, higher gage factors than those for
zone (from positive to negative piezoresistivity) was shown to CNT/thermosetting composites have been found for CNT/
correlate with polymer yielding, pinpointing that the MWCNT thermoplastic composites in the plastic regime.[55] This larger
network is not only able to self-sense strain, but also polymer sensitivity is concomitant with a nonlinear piezoresistive curve,
yielding and plasticity. which is usually driven by inelastic deformations. For example,
Under cycling compressive loading at incremental strains of Zetina-Hernández et al.[33] found that for 4 wt% MWCNT/PP
magnitude ecyc (Figure 9b), a reversible behavior of ΔR/R0 was composites, the tensile piezoresistive curve attains a gage factor
observed for strains below the polymer yield strain, but ΔR/R0 of 3.6 for strains below 1%, and the sensitivity is highly
was irreversible and cumulative for cycling strains above increased (GF 28.9) for larger strains, Figure 10. An indication
polymer yielding. As seen from Figure 9b, the irreversibility of the increased sensitivity with respect to thermosetting
of ΔR/R0 upon unloading is an indication of plasticity and polymers is seen in the maximum values of ΔR/R0 attained
damage accumulation, which can be quantified based on such a in Figure 10a (280%), compared to those in Figure 8a (3.3%).
permanent electrical response.[121] The authors further conducted loading-unloading tensile
Regarding flexural loading, the scarce studies seem to indi- experiments to prove that the transition zone (1% < e < 2%)
cate that the piezoresistive response is more sensitive under corresponds to polymer yielding, and that the high gage factors
uniaxial tension than under flexural loading,[110] although more observed for e > 2% correspond to polymer plasticity. Nanni
research is needed to unveil the reasons for that. The use of et al.[131] also confirmed that the yield point of the polymer (PET
piezoimpedance (instead of piezoresistance) is also an interest- in this case) can be identified by a transition zone with reduced
ing avenue that has been suggested by very few authors. It is sensitivity in the electro-mechanical signal, as seen in
argued that at high frequencies (1 MHz) alternating-current Figure 10b. Using 1, 2, and 4 wt% MWCNT/PET composites,
measurements (piezoimpedance) are more sensitive than those they demonstrated a strong correlation between polymer
in direct current (piezoresistance) due to the combined action yielding and the electrical resistance, whose particular features
Figure 9. Electrical response of a 0.3 wt% MWCNT/vinyl ester composite under axial compressive loading. a) Monotonic loading up to failure, b) cycling
loading, each cycle reaching a strain ecyc.[121] (Reproduced from ref. [121], with permission from Elsevier).
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which depend on the deformation level.[67,180,191,192] This macroscale in polymer composites with evidence of perfect
features may not be desirable for industrial applications, likely individual CNT alignment at the nanoscale is yet a challenge.
requiring implementation of some type of data signal lineariza- The effect of filler alignment on the piezoresistive response of
tion or compensation to be able to advance towards commercial carbon-based polymer composites has been scarcely explored,
devices.[193] with the majority of published studies focusing on
As a final remark of this section, a few recent works have been MWCNTs.[72,117,131,217,221] For aligned nanocomposites, the
conducted towards the exploration of hybrid architectures piezoresistive response has been studied in the direction of
combining CNTs and GSs mixed within polymer matri- CNT alignment (axial) and perpendicular to it (transverse).
ces.[67,194,195] According to the initial studies on the piezoresistive Table 2 summarizes the piezoresistive characteristics of different
response of hybrid nanocomposites, the piezoresistive sensitivity types of aligned CNT arrays and CNT/polymer composites with
might be controlled by adjusting the CNT-to-GS ratio.[67,195] The aligned CNTs, where the GFs were reported in at least two
use of hybrid CNT-GS fillers may also bring about improvements directions, viz. axial, transverse (shortened as “Tran” in such a
in the filler dispersion and load transfer from the matrix, Table), and/or randomly oriented. As seen from this table,
benefiting the mechanical properties of such nanocomposites.[196] tensile testing is undoubtedly the most commonly implemented
technique to explore the alignment effect on the piezoresistive
response, although bending experiments have also been
6. Piezoresistivity in Nanocomposites with reported. For the case of SWCNTs, most of the reports deal
with high SWCNT density systems without matrix, that is, in the
Aligned Fillers
form of buckypaper (BP)[140,222] or arrays.[226,227] The highest GF
Aligned carbon-based composites with anisotropic properties for a SWCNT aligned array (GF ¼ 75, under bending) was
are expected to render several advantages over those with reported by Cullinan and Culpepper,[227] where SWCNTs were
randomly oriented fillers.[197–199] One way of obtaining such deposited on a bending beam and aligned by the application of
anisotropic properties is by forming directionally aligned an alternating current electric field. This response evidences the
nanostructures within the polymer. In general, the formation high intrinsic piezoresistive sensitivity of CNTs when they are
of aligned structures within polymer matrices can be obtained directly loaded (a challenging task). The rest of the GFs reported
during the composite formation (e.g., by infiltration, fiber for systems with aligned SWCNTs usually range from 1 to 10,
drawing, or application of electric or magnetic fields) or after the although some of them are not directly loaded but bonded to a
incorporation of the fillers to the matrix (e.g., by stretching or beam.[140,222,226] Recently, Sengezer et al.[220] aligned SWCNTs by
polymer compression).[198] Several attempts to align CB,[200,201] means of an electric field in a photopolymerizable blend of
CNTs,[202–209] and more recently, graphenic platelets,[210] have acrylate resins, and investigated the piezoresistive response of
been reported, although prefect alignment at the macro- and the nanocomposites along the axial (parallel to alignment) and
nanoscales is yet a challenge. For the case of CNTs, excellent transverse (perpendicular to alignment) directions during
reviews regarding the formation of CNT assemblies with tensile loading. These authors reported higher piezoresistive
controlled orientation[211] and directional alignment of CNTs sensitivity for the transverse direction, see Table 2, which they
within polymers can be found elsewhere.[198] attributed to the interaction between misaligned and aligned
As a generally accepted outcome, the effective properties of the bridging structures, triggered by the Poisson’s contraction in the
composite material (e.g., mechanical, thermal, electrical) become transverse direction. For numerical comparison with existent
anisotropic upon alignment, that is, are strongly influenced by the literature, it is important to keep in mind that the transverse
filler orientation. Since the intensity of the magnetic fields required strain (calculated from the axial strain and Poisson’s ratio) was
to align CNTs within polymers seems to be unpractically used to calculate transverse GFs in Sengezer et al.[220] Another
high,[212,213] application of alternating current electric fields arises factor to bear in mind for comparative purposes is that in their
as a more suitable option.[214–217] The electric field approach relies work the load is always applied along the alignment direction
on the electric dipole moment induced on the
CNTs due to the different electrical properties
of the CNTs and surrounding medium. The
induced moments promote CNT-to-CNT inter-
actions, where forces and torques tend to orient
and interconnect the CNTs.[218,219] This strategy
has been applied, for example, to align MWCNTs
in dissolved polysulfone,[217] as well as to align
SWCNTs in photo-polymerizable resins.[215,220]
Figure 17 shows examples of polymer compo-
sites with evident mesoscopically aligned struc-
tures conformed by CNTs, where the application
of an alternating current electric field was used.
As seen from both figures, preferential align-
ment of CNT bundles has been achieved at the Figure 17. CNT/polymer composites aligned by electric fields. a) MWCNT/polysulfone
meso-scale, but certain degree of misalignment composite,[217] b) SWCNT/acrylate composite.[220] The arrows indicate the direction of the
is yet visible. To date, alignment at the electric field.
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Table 2. Summary of piezoresistive behavior of aligned CNT arrays and CNT/polymer composites with aligned CNTs.
Gage factor
Filler wt% Matrix (or substrate) Loading type Alignment method Axial Tran Random Ref.
[222]
SWCNT BP PET T Mechanical draw 7.2 N/A 1.3
[220]
0.03 Acrylate T Electric field 2 10 N/A
[223]
MWCNT BP PET B Magnetic field 2.1 4.5 2.3
Array Polyimide T Stretching 20 N/A 3 [224]
[225]
Array Glass fiber/epoxy T CVD 8 1.3 N/A
[131]
1.0 PET T Extrusion 3.9 4.6 N/A
43 Epoxy T Stretching 0 0.25 N/A [117]
[217]
0.75 PSF T Electric field 1.5 N/A 0.7
[221]
5.0 PC T Injection molding 3.7 6.2 2.6
Acronyms: T ¼ Tensile, B ¼ Bending, ¼ Bonded to a beam or to a larger tensile specimen, N/A ¼ Not available, BP ¼ Buckypaper, PC ¼ Polycarbonate, PSF ¼ Polysulfone,
PET ¼ Polyethylene terephthalate, CVD ¼ Chemical vapor deposition.
and the configuration of the longitudinal and transverse Only a few authors have compared the piezoresistive response
electrodes are changed; different electrode configurations could of CNT/polymer composites along both the alignment (axial) and
originate a different piezoresistive response per se. For the case transverse directions,[117,131,220,221] generally finding that the GF in
of MWCNTs, the piezoresistive response of several arrays of the transverse direction is higher than that in the axial direction, see
aligned MWCNTs[223–225,228,229] and aligned MWCNT/polymer Table 2. It is hypothesized that the reasons for this are the significant
composites[72,117,131,217,221] have also been reported. In general, change in CNT-to-CNT lateral contact and the breakdown of the few
GFs of aligned MWCNTs and MWCNT composites range from conductive misaligned pathways bridging the aligned ones upon
0.04 to 20. Thermosetting (epoxy) and thermoplastic (poly- strain application. However, more systematic studies are still needed
sulfone and polycarbonate) polymers have been used as host to better elucidate these mechanisms, and to investigate how several
matrices for aligned MWCNT networks with concentrations factors such as the filler concentration, polymer rheology, alignment
ranging from 0.02[72] to 67 wt%.[117] As a general outcome, all the degree, CNT length, functionalization, and loading configuration,
studies confirm that the piezoresistive sensitivity becomes affect the electromechanical response of polymer nanocomposites
anisotropic by aligning the CNTs, see Table 2. Some authors with aligned carbon fillers.
have found higher GFs for the alignment direction than for the
randomly distributed case,[217,221,222,224] which may be explained
by the better strain transfer and increased contact resistance 7. Concluding Remarks and Perspectives
along the aligned direction. To illustrate this, Figure 18 shows the
The use of carbon-based polymer nanocomposites for develop-
tensile piezoresistive response of a 200 μm thick MWCNT/PSF
ing smart piezoresistive materials which are capable of sensing
composite film loaded along the alignment (axial) direction,
their own elastic strain, plasticity, and damage has been
compared to the response of a film with randomly oriented
reviewed. Upon reaching percolation, polymer composites
CNTs.[217]
which are otherwise electrically insulating materials present
an electrical conductivity whose changes as a function of strain
can be employed for self-sensing of strain and damage. Carbon
materials such as graphite, carbon black, carbon nanotubes, and
lately few- and multi-layer graphene are ideal candidates to act as
polymer fillers to such an aim. The coupled electromechanical
response of such polymer nanocomposites depend on several
factors related to the filler (nanostructure architecture, dimen-
sions, number of layers, functional groups), to the polymer
matrix (dielectric constant, processing viscosity) and to the filler
dispersion within the matrix. From the geometrical aspects of
the filler, the excluded volume is one of the key parameters that
influences the piezoresistive sensitivity of polymer composites.
It is expected that loosely connected networks with low filler
concentrations, high excluded volume and high number of filler-
to-filler contact points render higher piezoresistive sensitivity.
Creation and destruction of conductive pathways upon loading,
Figure 18. Piezoresistive response of MWCNT/PSF composite films with change in contact resistance and change in tunneling resistance
aligned and randomly oriented CNTs. are believed to be the main mechanisms governing the
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piezoresistive response of these smart materials. The use of graphenic platelets and the possibility of their top-down synthesis
piezoimpedance and piezocapacitance for strain and damage in large scales are features which make them also very attractive for
sensing in this kind of polymer composites is also an interesting piezoresistive applications. As a future trend, hybrid combinations
approach that deserves further exploration. The current of one dimensional carbon nanotubes and two-dimensional
applications of thermosetting and thermoplastic piezoresistive graphenic platelets may become optimal topological combinations
materials are expected to provide the automotive, aerospace, for piezoresistive strain sensing applications, but the optimization
transportation and energy industries with the next generation of the hybrid architecture is yet to come.
of smart materials. Especially for thermosetting polymers, the
applications of these nanocomposites are rapidly evolving
towards self-sensing of strain and damage in fiber-reinforced Appendix A: Compendium of Piezoresistive
multiscale hierarchical composites, for virtually every industrial
Behavior of Carbon Filled Polymer Composites
application of composites which demand high load bearing
capacity and self-sensing. The applications of carbon filled The main piezoresistive features of about 90 works are collected
elastomeric materials, on the other hand, focus more on sensors in the parameters listed in Table A1. Such a table is organized
for human motion, soft skins, smart wearable sensors and by filler type and includes thermosetting (TS), thermoplastic
robotics, whose main requisite is large deformations. However, (TP) and elastomeric (ES) matrices, as well as the correspond-
aspects such as nonlinearity, cycling reproducibility, undesired ing filler concentration (wt%) and loading type (tension,
viscoelastic response, and hysteresis, are practical issues that compression or bending). The main features of the piezor-
need to be resolved towards further development of commercial esistive response of the material are captured by four
devices based on these materials. parameters, referring to its linear (L) or nonlinear (NL)
Because of their elongated geometry, carbon nanotubes stand character, maximum strain sensing capability (emax), extend
today as ideal candidates for fillers in this kind of piezoresistive of linear piezoresistivity (eL) and piezoresistive sensitivity (GF).
materials. Controlling the morphology an orientation of the The difference between eL and emax provides an indication of
carbon nanotube networks, for example, by aligning them in a nonlinear piezoresistivity. All concentrations are reported in
preferential direction, may render tailored piezoresistive sensitivi- weight (wt%), so all values originally reported in volume
ties. However, the higher surface area of two-dimensional concentration (vol%) were converted to weight (and thus,
Table A1. Summary of piezoresistive behavior and gage factors of polymer composites filled with carbon nanostructures.
Piezoresistivity
Filler wt% Matrix (or substrate) Loading type L/NL emax (%) eL (%) GF Ref.
[71]
Carbon black 0.5 Epoxy T NL 6 1 6
[72]
12 Epoxy T NL 4 1 27.7
[73]
50.8 HDPE C L 50 50 3.2
[74]
13.4 PP T NL 3 1.5 6.6
[75]
5.2 PP T L 3 3 30
[76]
9.2 HDPE T NL 25 15 10
[77]
12.6 HDPE T NL 90 35 4.5
[78]
3 PVDF T NL 9 5 3
[79]
33 Natural rubber T NL 90 7 17
[80]
30.6 Natural rubber T NL 250 100 12
[82]
10 Polyisoprene T NL 40 10 15
[83]
9.0 Silicone rubber C NL 25 2.5 3.6
50 Silicone rubber C NL 25 2.5 4.4 [83]
[73]
50.2 Silicone rubber C NL 50 13 4.2
35 Natural rubber C L 16.7 16.7 2.7 [85]
[96]
Graphite 16.7 Epoxy B N/A N/A N/A 22
[95]
18 Polyimide B NL N/A N/A 16.8
[91]
12.5 PP T NL 0.6 0.3 135
[92]
37.5 HDPE C NL 35 5 14
(Continued)
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Piezoresistivity
Filler wt% Matrix (or substrate) Loading type L/NL emax (%) eL (%) GF Ref.
[6]
27.6 HDPE C NL 10 7 7
[93]
49.4 Silicone rubber C NL 15 3 44
3.1 Silicone rubber C NL 0.5 0.3 16.7 [94]
SWCNT BP PDMS T NL 280 40 0.82 (0 < e < 0.4) [20]
[232]
BP Epoxy T NL 0.95 0.6 2.2
[232]
BP R-Epoxy T NL 15 3 0.60
[140]
BP PET T L 2.0 N/A 1.0
BP PDMS T NL 30 N/A 5.0 (0.2< e < 0.3) [140]
[233]
BP N/A T L 1.0 1.0 1.25
[222]
BP PET T L 0.65 N/A 1.30 to 7.19
[113]
0.2 Epoxy B NL 3.0 1.0 3.6
[122]
0.5 PMMA B L 0.13 0.13 5.2
[122]
10 PMMA B L 0.13 0.13 0.95
[123]
2.0 PVDF B L 0.25 0.25 6.2
[124]
2.0 PVDF B L 0.6 0.6 4.43
8.0 TPU T NL 60 20 0.05 to 0.10 (e < 0.2) [137]
[145]
1.0 SBS T L 5 5 3 to 4.5
[232]
MWCNT BP Epoxy T NL 1.07 0.6 0.85
[232]
BP R-Epoxy T NL 30 7 0.70
[135]
BP TPU T NL 400 0 4 to 69
[234]
BP TPU T NL 12 0 5 to 44
[71]
0.1 Epoxy T NL 6.0 1.5 3.4 to 4.3
[114]
5.0 Epoxy T (C) L 0.6 0.6 3.8 (4.9)
[114]
1.0 Epoxy T (C) NL 0.6 0.1 22.4 (7.1)
0.2 Epoxy C NL 12 2 4.2 [115]
[116]
0.3 Epoxy T NL 7.0 1.9 1.42
[117]
53 Epoxy T L 1.0 1.0 1.0 to 1.5
[110]
0.3 Epoxy T NL 3.5 2.0 0.43
0.3 Epoxy B NL 3.5 <0.3 <0.1 [110]
[72]
0.3 Epoxy T NL 4.0 1.0 4.1
[112]
0.3 Vinyl ester T L 1.3 1.3 2.60
0.3 Vinyl ester C NL 20 1.0 0.91 (EL), 9.37 (PL) [112]
[128]
5.0 PC T L 1.7 1.0 7.0
1.0 PEO T NL 1.0 0.8 3.7 [129]
[32]
1.0 PMMA T NL 1.0 0.2 15.3
[32]
3.0 PMMA T NL 1.0 0.2 4.6
[130]
1.0 PSF T NL 5.0 1.0 0.73
[131]
1.0 PET T NL 5.0 0.5 0.71 (EL), 3.9 (PL)
[126]
0.75 PVDF B L 0.3 0.3 3.91
[74]
7.6 PP T NL 3 1.0 1.3
[33]
4.0 PP T NL 9.7 1.0 3.56 (EL), 28.9 (PL)
[33]
8.0 PP T NL 8.0 1.0 1.23 (EL), 23.9 (PL)
[139]
1.4 PDMS T NL 50 20 1 to 2
2.3 TPU T NL 1000 0 5 (e ¼ 2.5) [136]
(Continued)
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Piezoresistivity
Filler wt% Matrix (or substrate) Loading type L/NL emax (%) eL (%) GF Ref.
[138]
2.0 TPU T NL 30 0 2 to 6
[134]
6.0 TPU T NL 100 0 0.09 to 2.64
[145]
1.0 SBS T L 5 5 2 to 8
[146]
4.0 SBS T L 50 10 3 to 120
[146]
4.0 SBS B L 0.065 0.065 40 to 100
[142]
3.0 Silicone rubber T NL 10 0 2.0 to 9.46
[153]
4.0 TPU T NL 100 0 21.9 to 126
2.0 SEBS T NL 80 N/A 1.2 to 2.2 [143]
4.0 SEBS T NL 80 N/A 1.5 to 2.7 [143]
[189]
Graphenic sheets GP PDMS T NL 100 10 2
[97]
GP PDMS T L 1.6 1.6 546
[171]
GP PMMA B L 0.8 0.8 53
[235]
GP PDMS T NL 26 6 34.3
2.2 PVDF T L 1.2 1.2 12.1 [184]
7.0 PVDF T L N/A N/A 5 [184]
[185]
5.0 PVDF B L 0.15 0.15 4 to 11
[179]
3.0 Epoxy B L 0.1 0.1 11.4
2.0 Epoxy B NL 2.6 0.6 56.7 [191]
[180]
1.0 Epoxy B NL 2.35 1 63.5
[180]
2.0 Epoxy B NL 2.35 1 23.4
[183]
2 Epoxy T NL 2 1 12.8
[172]
2.7 Epoxy T L N/A N/A 45
[173]
2.0 Epoxy T NL 3 0.5 24
[173]
5.0 Epoxy T NL 3 0.5 12
[181]
1.0 Vinyl ester B NL 1.5 0.3 33
[174]
0.5 PDMS T NL 95 45 0.4
[178]
15.6 PDMS T L 2.0 2.0 233
[178]
31 PDMS T L 2.0 2.0 3.9
[182]
20 PDMS B NL 9.0 6 30
30 PDMS B NL 9.0 6 10 [182]
[176]
1.0 TPU C NL 55 12 6.2
2.0 TPU C NL 90 60 2.45 [177]
[61]
19 EB T NL 20 10 53
[61]
21 EB T NL 20 10 33
Acronyms: T ¼ Tensile, C ¼ Compressive, B ¼ Bending, ¼ Bonded to a beam or to a larger tensile specimen, L ¼ Linear, NL ¼ Nonlinear, emax ¼ Maximum strain registered
by the electrical signal, eL ¼ Maximum strain corresponding to approximately linear piezoresistivity, EL ¼ Elastic region, PL ¼ Plastic region, N/A ¼ Not available,
BP ¼ Buckypaper, GP ¼ Graphene-paper, R-Epoxy ¼ Rubber-modified epoxy, PP ¼ Polypropylene, PC ¼ Polycarbonate, HDPE ¼ high denstity polyethylene, PET ¼
polyethylene terephthalate, PSF ¼ Polysulfone, PEO ¼ Polyethylene oxide, PMMA ¼ Polymethyl methacrylate, PDMS ¼ Polydimethylsiloxane, TPU ¼ Thermoplastic
polyurethane, PVDF ¼ Polyvinylidene fluoride, EPDM ¼ Ethylene propylene diene rubber, EB ¼ ethylene-butene, SBS ¼ styrene-butadiene-styrene, SEBS ¼ styrene-
ethylene-butylene-styrene.
represent our best estimate). For conversions from vol% to wt% factor was directly provided by the original reference. In the
the densities of the carbon nanostructures were taken as cases that such a number was not directly provided, but the
1800 kg m3 (carbon black),[80] 2200 kg m3 (graphite),[230] required piezoresistive curve was published, the available data
2100 kg m3 (MWCNT),[231] and 1870 kg m3 (SWCNT).[231] was digitalized and the GFs reported in Table A1 were
For the majority of the cases, the numerical value of the gage estimated.
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