A hierarchically porous AgNW-TPU composite with “pores-in-pore” architecture for bifunctional flexible sensors and energy harvesters

The integration of high flexibility and high sensitivity in electronic materials remains a major challenge in wearable applications. This study presents a hierarchically porous thermoplastic polyurethane (TPU) film featuring a unique “pores-in-pore” architecture—with small-sized pores uniformly distributed within the walls of large-sized pores—as an ideal platform for multifunctional flexible electronics. The structure is functionalized with silver nanowires (AgNWs) at varying concentrations, enabling tunable electrical conductivity while preserving the intrinsic flexibility of the TPU matrix (elongation at break up to 1200 %). The resulting AgNW-TPU film achieves integrated sensing and energy harvesting capabilities: as a strain sensor, it exhibits high sensitivity (gauge factor > 780) and a broad sensing range (>15 % strain), attributable to the reversible disconnection and reconnection of the AgNW conductive network within the elastic porous framework during deformation; as a single-electrode triboelectric nanogenerator (TENG), it efficiently harvests mechanical energy via contact-separation, with a peak power density of 7.8 nW/cm 2, capable of continuously powering sensing units. This integration of highly sensitive strain detection and efficient energy conversion mechanisms within a single material platform not only resolves the inherent conflict between flexibility and electronic functionality but also enables truly self-powered sensing. This work provides a scalable and versatile integrated solution for next-generation wearable electronics, self-powered sensing systems, and adaptive energy devices.

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