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In recent years, nanocomposites based on various nano-scale carbon fillers, such as carbon nanotubes (CNTs), are increasingly being thought of as a realistic alternative to conventional smart materials, largely due to their superior electrical properties. Great interest has been generated in building highly sensitive strain sensors with these new nanocomposites. This article reviews the recent significant developments in the field of highly sensitive strain sensors made from CNT/polymer nanocomposites. We focus on the following two topics: electrical conductivity and piezoresistivity of CNT/polymer nanocomposites, and the relationship between them by considering the internal conductive network formed by CNTs, tunneling effect, aspect ratio and piezoresistivity of CNTs themselves, etc. Many recent experimental, theoretical and numerical studies in this field are described in detail to uncover the working mechanisms of this new type of strain sensors and to demonstrate some possible key factors for improving the sensor sensitivity.

The electrical properties of polymer nanocomposites containing a small amount of carbon nanotube (CNT) are remarkably superior to those of conventional electronic composites. Based on three-dimensional (3D) statistical percolation and 3D resistor network modeling, the electrical properties of CNT nanocomposites, at and after percolation, were successfully predicted in this work. The numerical analysis was also extended to investigate the effects of the aspect ratio, the electrical conductivity, the aggregation and the shape of CNTs on the electrical properties of the nanocomposites. A simple empirical model was also established based on present numerical simulations to predict the electrical conductivity in several electronic composites with various fillers. This investigation further highlighted the importance of theoretical and numerical analyses in the exploration of basic physical phenomena, such as percolation and conductivity in novel nanocomposites.

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