A highly sensitive stretchable constraint fiber mat sensor with tailored near-zero Poisson’s ratio for very early stage of battery over charge/overdischarge monitoring

Battery state monitoring is crucial for safe operation and efficient management of lithium-ion battery (LIB) systems, but early stage of timely and accurate diagnosis remains challenging. Herein, we propose to utilize a highly sensitive stretchable strain sensor to in-situ monitor the slight strain variation of cells during charge and discharge, through which the state of the battery can be accurately reflected. The high sensing capability is realized by tailoring the Poisson’s ratio of low-modulus conductive fiber mats through a facile constraint manner. The non-uniform strain distribution together with the near-zero Poisson’s ratio synergistically result in the superior sensing performance, including ultralow strain detection limit (0.006%), high strain sensitivity particularly under small strains (gauge factor of 116.1 between 0 and 2% strain), and high strain resolution under large deformations. When being practically utilized for LIB monitoring, the constraint fiber mat sensor can produce instant resistance response reflecting the cell capacity, and offer timely warning signal once the cell is overcharged or overdischarged. The developed stretchable strain sensor possesses comprehensive advantages of low mechanical constraint, tailorable small size, easy integration and conformality to cells, and little temperature interference, which would serve as a promising candidate for future battery state analysis and safety monitoring.