A high-sensitivity pressure conduction sensor is presented. The present
invention includes a pair of locally resilient conductive layers and a
locally resilient pressure conduction composite disposed between and
contacting both conductive layers. Alternate embodiments include at least
three locally resilient conductive layers and at least two locally
resilient pressure conduction composites, each having a critical
percolation threshold. Each composite is disposed between and contacting
two conductive layers in a multi-layer fashion. Other embodiments include
a locally resilient pressure conduction composite, a flexible substrate
completely surrounding the composite so as to seal it therein, and a pair
of electrical leads contacting the composite and terminating outside of
the flexible substrate. Pressure conduction composites are composed of a
plurality of conductive particles electrically isolated within a
non-conductive matrix. Conductive particles are loaded so as to have a
volume fraction approaching the critical percolation threshold of the
material system and exhibit a conductance that greatly increases with
pressure. Sensors may be arranged to form one or more arrays including
planar and conformal configurations. The present invention has immediate
application in keyboards, intrusion systems, control systems, submarines,
ships, sonobuoys, doors, and switches.