Conductive polymer composite membranes such as multi-walled carbon nanotubes (MWCNTs)/polydimethylsiloxane (PDMS) membranes are important for flexible strain sensors. However, ultra-thin MWCNTs/PDMS films (<20 μm) have rarely been studied, mainly due to inherent difficulties in fabricating processes such as the peeling and transferring. In this work, the filtration-fromsuspension (FFS) method was used to fabricate ultra-thin layer of MWCNTs (buckypapers, BPs). Subsequently, spin-coating PDMS on the BPs was carried out, and the penetration of PDMS into BPs was promoted under vacuum conditions to obtain the MWCNTs/PDMS composite films. The elastic nature of PDMS assisted in peeling the composite films off the filter papers. Compared with the other methods, the fabrication method of MWCNTs/PDMS membranes in this paper is more time-efficient and reliable. A comprehensive study on the fabricated MWCNTs/PDMS membranes with different compositions was carried to understand the mechanical and electrical performance under static and cyclic loading conditions. The obtained stress-strain and resistancestrain curves show that the modulus of the MWCNTs/PDMS membrane can be significantly increased over 8-10 times compared with pure PDMS membranes. The near exponential relationship between the resistance change versus the strain implies the MWCNTs/PDMS membranes are suitable for strain sensors. Moreover, we find there is a stability transition point in thickness at which the MWCNTs/PDMS composite membrane exhibits the best overall integrated performance. At this point, the changes before and after cyclic loading/unloading on composite membranes is almost negligible, implying the good reliability of the sensing membranes. This study has demonstrated the feasibility of fabricating ultrathin MWCNTs/PDMS membranes for wearable sensors.
K E Y W O R D Smechanical and electrical properties, strain sensing behaviors and stability, transition point and reliability, ultrathin MWCNTs/PDMS composite membrane