Ultra‐Tough Waterborne Polyurethane‐Based Graft‐Copolymerized Piezoresistive Composite Designed for Rehabilitation Training Monitoring Pressure Sensors

Abstract Effective training is crucial for patients who need rehabilitation for achieving optimal recovery and reducing complications. Herein, a wireless rehabilitation training monitoring band with a highly sensitive pressure sensor is proposed and designed. It utilizes polyaniline@waterborne polyurethane (PANI@WPU) as a piezoresistive composite material, which is prepared via the in situ grafting polymerization of PANI on the WPU surface. WPU is designed and synthesized with tunable glass transition temperatures ranging from −60 to 0 °C. Dipentaerythritol (Di‐PE) and ureidopyrimidinone (UPy) groups are introduced, endowing the material with good tensile strength (14.2 MPa), toughness (62 MJ −1 m −3 ), and great elasticity (low permanent deformation: 2%). Di‐PE and UPy enhance the mechanical properties of WPU by increasing the cross‐linking density and crystallinity. Combining the toughness of WPU and the high‐density microstructure derived by hot embossing technology, the pressure sensor exhibits high sensitivity (168.1 kPa −1 ), fast response time (32 ms), and excellent stability (10 000 cycles with 3.5% decay). In addition, the rehabilitation training monitoring band is equipped with a wireless Bluetooth module, which can be easily applied to monitor the rehabilitation training effect of patients using an applet. Therefore, this work has the potential to significantly broaden the application of WPU‐based pressure sensors for rehabilitation monitoring.