Ultra-Durable Wearable Strain Sensors via Synergistic Filler Hybridization and Interfacial Bonding

Wearable strain sensors have shown significant progress in detecting subtle physiological strains (e.g., heartbeat, pulse) and large deformations (e.g., elbow bending). However, long-term stability under multifactorial environmental conditions remains a critical challenge for practical wearable electronics. Here we proposed a synergistic strategy combining filler hybridization and interfacial bonding to construct a covalently crosslinked network in styrene butadiene rubber (SBR)/carbon nanotubes (CNTs) composites. This method covalently anchored thiol-functionalized CNTs into a vulcanized SBR matrix via thermal crosslinking. The composites retained robust strain-sensing conduction pathways after thermo-oxidative aging and exposure to acidic/alkaline/saline environments, maintaining a detection range of 1%–220%, a resolution of 0.5% (sufficient for most human physiological and motion signals, comparable to 0.4% limit in recent sensors), and a response time of 88 ms (matching sub-100 ms of state-of-the-art sensors). This work establishes novel design principles for durable sensors and offers a practical solution for reliable monitoring in high-risk scenarios.