Dual-plasticized TPU/PVC gel with dielectric–conductive properties for triboresistive position sensors

Flexible self-driven position sensors are essential components for intelligent wearables, human–computer interaction, and soft robotics, requiring excellent mechanical compliance, high positioning accuracy, and simplified device structures. Here, we present a novel single-layer triboelectric nanogenerator (S-TENG) serving as a triboresistive position sensor (TPS) based on dual-plasticized thermoplastic polyurethane (TPU)/polyvinyl chloride (PVC) gel (TPDP gel), constructed via a synergistic plasticization strategy with dibutyl adipate (DBA) as the primary plasticizer and propylene carbonate (PC) as the secondary plasticizer. This strategy optimizes the gel’s dielectric and insulating properties, increasing the dielectric constant from 4.2 to 7.8 (an 85% enhancement) and reducing the leakage current density to 0.02 μA·cm⁻². Based on the optimized gel, a single-layer integrated S-TENG was fabricated, exhibiting 50 V open-circuit voltage and 45.1 mW·m⁻² maximum power density, while maintaining stable performance under 100% strain, 180° bending, and 360° twisting. Utilizing the gel’s intrinsic resistive properties, one-dimensional (1D) and two-dimensional (2D) TPS were constructed, achieving 2.785% and 3.975% relative errors at 0% and 100% strain, respectively, and < 4 mm positioning deviation in a 7 cm × 7 cm area. The proposed TPS features a simplified structure and high stretchability, providing a new approach for flexible self-driven sensing systems.