Apparatus and method for nanocomposite sensors

An apparatus, comprising:

• a polymer base having at least one edge;
• a nanocomposite embedded in the polymer base in a continuous pattern having a first end and a second end;
• a first electrical terminal;
• and
• a second electrical terminal,
• wherein the first electrical contact contacts with the first end of the nanocomposite pattern, wherein the second electrical contact contacts the second end of the nanocomposite pattern, and the nanocomposite includes a polymer matrix and a plurality of at least one of conductive nanotubes, conductive nanowires, conductive particles and conductive flakes suspended in the polymer matrix,
• wherein the density of the plurality of the at least one of nanotubes, nanowires, particles and flakes is such that the nanocomposite is conductive;
• and
• wherein the first and second electrical terminals are configured for the measurement of at least one of a voltage, a current and a resistance across the patterned pizeoresistive nanocomposite.

A method for fabricating a sensing material for a sensor, comprising:

• providing a stamp having a continuous raised pattern;
• dipping the stamp into a conductive nanocomposite including a plurality of at least one of conductive nanotubes, conductive nanowires, conductive particles and conductive flakes such that an amount of conductive nanocomposite adheres to the continuous raised pattern;
• using the stamp to imprint a continuous pattern of the conductive nanocomposite to a substrate;
• partially curing the imprinted pattern of conductive nanocomposite on the substrate;
• pouring a polymer mixture onto the imprinted pattern of conductive nanocomposite such that the imprinted pattern is submerged;
• curing the polymer mixture;
• and
• removing the polymer with imprinted conductive nanocomposite from the substrate.

A method for fabricating a sensing material for a sensor, comprising:

• providing a substrate and applying a screen to a side of said substrate;
• providing a programmable focused laser beam configured to define a pattern on the screen;
• utilizing the programmable focused laser beam to burn a continuous pattern into the screen, thereby forming one or more grooves in the screen wherein the substrate is accessible through the grooves;
• pouring an amount of a conductive nanocomposite including a plurality of at least one of conductive nanotubes, conductive nanowires, conductive particles and conductive flakes into the grooves and removing excess amounts;
• removing the screen to leave behind an imprinted pattern of conductive nanocomposite on the substrate;
• partially curing the imprinted pattern of conductive nanocomposite on the substrate;
• pouring a polymer mixture onto the imprinted pattern of conductive nanocomposite such that the imprinted pattern is submerged;
• curing the polymer mixture;
• and
• removing the polymer with imprinted conductive nanocomposite from the substrate.

A method for forming a conductive nanocomposite, comprising:

• adding a polymer into a first organic solvent solution and allowing the polymer to dissolve;
• dispersing a conductive nanofiller into a second organic solvent solution and stirring;
• adding the first organic solvent solution to the second organic solvent solution, forming a mixture, and stirring the mixture;
• evaporating the first and second organic solvent solutions from the mixture;
• and
• adding a polymer curing agent to the mixture, forming a conductive nanocomposite.