Development of deformation sensors based on multiphase polymer nanocomposites using self-orientation and nanofiller localization - numerical simulation and experimental investigation (EffiSens)

• Applicants: Dr.-Ing. Martin Ganß; Professor Dr. Tom Lahmer; Dr.-Ing. Ulrike Staudinger
• Subject Area: Synthesis and Properties of Functional Materials ; Computer-Aided Design of Materials and Simulation of Materials Behaviour from Atomic to Microscopic Scale ; Experimental and Theoretical Physics of Polymers ; Polymer Materials
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 570602060

Developing sensors and sensor technologies has led to significant progress in process and product development in numerous areas, particularly due to the precise and multi-sensory recording of physical variables and the optimization that this makes possible. One promising class of sensors is piezoresistive sensors, which convert changes in mechanical loads into electrical signals. Electrically conductive polymer nanocomposites with carbon-based fillers are particularly suitable as starting materials for such deformation sensors. The sensory properties of these polymer nanocomposites are essentially based on changes in their electrical resistance when a mechanical load is applied. The project aims to combine experimental approaches and numerical modeling to research and further develop efficient deformation sensors based on electrically conductive multiphase polymer/CNT nanocomposites. The state-of-the-art comprises mainly polymers consisting of one phase. By using and specifically localizing the nanofillers in a component or phase of immiscible polymer blends or microphase-separated block copolymers, the filler dispersion can be improved and the sensitivity of the sensor increased. However, there is a need for further research to achieve high signal sensitivity and high reproducibility at the same time. The research consortium aims to develop new approaches for the development of deformation sensors based on electrically conductive polymer nanocomposites using the self-assembly of multiphase block copolymers to adjust specific sensor properties. To this end, it is planned to couple and compare experimental work on structure-property correlation with numerical multi-scale simulation methods using representative volume elements. In addition to material development with new concepts for the generation of efficient filler networks, the development of a new, innovative, and situation-adapted sensor design is also planned. This also includes the targeted modification of the properties through constructive adjustments to the macroscopic sensor geometry using extrusion-based additive manufacturing. The project aims to qualify the BCP/CNT nanocomposite for the fused layer modeling process and to develop a material-appropriate process control.

• DFG Programme: Research Grants