In recent years, soft and flexible strain sensors have found application in wearable devices for monitoring human motion and physiological parameters. Conductive textile-based sensors are good candidates for developing these sensors. However, their robust electro-mechanical connection and susceptibility to environmental factors are still an open challenge to date. In this work, the manufacturing process of a silicone-textile composite resistive strain sensor based on a conductive resistive textile encapsulated into a dual-layer of silicone rubber is reported. In the working range typical of biomedical applications (up to 50%), the proposed flexible, skin-safe and moisture resistant strain sensor exhibited high sensitivity (gauge factor of -1.1), low hysteresis (maximum hysteresis error 3.2%) and ease of shaping in custom designs through a facile manufacturing process. To test the developed flexible sensor, two applicative scenarios covering the whole working range have been considered: the recording of the chest wall expansion during respiratory activity and the capture of the elbow flexion/extension movements.
Keywords: flexible sensors; polymer encapsulation; sensors for physiological monitoring; strain sensors; wearable sensors.