Facile Fabrication of Electrically Conductive Low-Density Polyethylene/Carbon Fiber Tubes for Novel Smart Materials via Multiaxial Orientation

Electromechanical sensors are indispensable components in functional devices and robotics application. However, the fabrication of the sensors still maintains a challenging issue that high percolation threshold and easy failure of conductive network are derived from uniaxial orientation of conductive fillers in practical melt processing. Herein, we reported a facile fabrication method to prepare a multiaxial low-density polyethylene (LDPE)/carbon fibers (CFs) tube with bidirectional controllable electrical conductivity and sensitive strain-responsive performance via rotation extrusion technology. The multidimensional helical flow is confirmed in the reverse rotation extrusion, and the CFs readily respond to the flow field leading to a multiaxial orientation in the LDPE matrix. In contrast to uniaxial LDPE/CF composites, which perform a "head to head" conjunction, multiaxial-orientated CF networks exhibit a unique multilayer structure in which the CFs with distinct orientation direction intersect in the interface, endowing the LDPE/CF composites with a low percolation threshold (15 wt %) to those of the uniaxial ones (∼35 wt %). The angles between two axes play a vital role in determining the density of the conductive networks in the interface, which is predominant in tuning the bending-responsive behaviors with a gauge factor range from 12.5 to 56.3 and the corresponding linear respond region from ∼15 to ∼1%. Such a superior performance of conductive LDPE/CF tube confirms that the design of multiaxial orientation paves a novel way to facile fabrication of advanced cost-effective CF-based smart materials, shedding light on promising applications such as smart materials and intelligent engineering monitoring.