Journal Article

PUBDB-2025-02179

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Structural and Electromechanical insights into Thermoplastic Polyurethane/3D Hybrid Carbon Nanocomposites towards Strain Sensor Applications

Babu, V.Extern* ; Sochor, B.Extern*DESY* ; Gupta, A.Extern* ; Koyiloth Vayalil, S. (Corresponding author)Extern*DESY*

2026
ACS Publications Washington, DC

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Please use a persistent id in citations: doi:10.1021/acsomega.5c08617  doi:10.3204/PUBDB-2025-02179

Abstract: Incorporation of different dimensional carbon allotropes within elastomeric matrices has been established as an effective strategy to fabricate functional conductive polymer nanocomposites (PNC). In this work, a higher dimensional 3D hybrid carbon nanofillers - comprising the synergistically integrated multi-walled carbon nanotubes immobilized into few-layers graphene – were incorporated into thermoplastic polyurethane (TPU) matrix, to demonstrate its effectiveness as a strain sensor. The conductive films fabricated through a simple solution casting technique, in which the mechanical, electrical and strain sensing characteristics are studied in view of filler’s distribution, structural confinement, and interfacial interactions. Analyses using wide-angle X-ray scattering, Raman spectroscopy, and tensile testing, revealed a higher degree of filler reinforcement within TPU moieties, indicating the pronounced interfacial interactions. Further, the tensile modulus heightened significantly with filler loading above their percolation threshold (363% for 20wt% loading). The structural features of dispersed filler aggregates were explored through an iterative model fitting of the ultra-small angle X-ray scattering (USAXS) data, along with scanning electron microscopy (SEM). As a strain sensor, the films displayed a superior working-strain Gauge Factor (GF=123), with an exceptional stability under both unidirectional and cyclic strain. Further, a large strain GF of 601.5 was evidenced for the composites with higher 3D filler loading. The findings provide a fundamental understanding, alongside validating the potential of hybrid carbonaceous fillers for the fabrication of PNCs with futuristic applications.

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Contributing Institute(s):

1. PETRA-D (FS-PETRA-D)
2. DOOR-User (DOOR ; HAS-User)

Research Program(s):

1. 632 - Materials – Quantum, Complex and Functional Materials (POF4-632) (POF4-632)
2. 6G3 - PETRA III (DESY) (POF4-6G3) (POF4-6G3)
3. INDIA-DESY - INDIA-DESY Collaboration (2020_Join2-INDIA-DESY) (2020_Join2-INDIA-DESY)
4. FS-Proposal: I-20221139 (I-20221139) (I-20221139)

Experiment(s):

1. PETRA Beamline P03 (PETRA III)

Appears in the scientific report 2026

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Database coverage:
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