Continuous Meter-Scale Synthesis of Weavable Tunicate Cellulose/Carbon Nanotube Fibers for High-Performance Wearable Sensors

Weavable sensing fibers with superior mechanical strength and sensing functionality are crucial for the realization of wearable textile sensors. However, in the fabrication of previously reported wearable sensing fibers, additional processes such as reduction, doping, and coating were essential to satisfy both requirements. The sensing fibers should be continuously synthesized in a scalable process for commercial applications with high reliability and productivity, which was challenging. In this study, we first synthesize mass-producible wearable sensing fibers with good mechanical properties and sensing functionality without additional processes by incorporating carbon nanotubes (CNTs) into distinct nanocellulose. Nanocellulose extracted from tunicate (TCNF) is homogeneously composited with single-walled CNTs, and composite fibers (TCNF/CNT) are continuously produced in aligned directions by wet spinning, facilitating liquid-crystal properties. The TCNF/CNT fibers exhibit a superior gas (NO₂)-sensing performance with high selectivity and sensitivity (parts-per-billion detection). In addition, the TCNF/CNT fibers can endure complex and harsh distortions maintaining their intrinsic sensing properties and can be perfectly integrated with conventional fabrics using a direct weaving process. Our meter-scale scalable synthesis of functional composite fibers is expected to provide a mass production platform of versatile wearable sensors.