Immiscible polymer blends based on polypropylene/thermoplastic polyurethane (PP/TPU) are interesting host multiphase systems for the incorporation of low concentrations of conductive carbon black (CB) particles. The enhancement of conductivity (and the lower critical CB content for percolation) in the PP/TPU blend is achieved via double percolation, that is, structural and electrical. The CB particles form chainlike network structures within the TPU phase, which exhibit phase continuity of elongated particles within the PP matrix. Moreover, scanning electron microscopy and dynamic mechanical thermal analysis studies indicated that the incorporation of CB particles into the PP/TPU blend has a "compatibilizing" effect, resulting in an enhanced interaction between the two polymers. Extruded PP/TPU/CB filaments produced by a capillary rheometer process at various shear rates were examined as sensing materials for a homologous series of alcohols, that is, methanol, ethanol, and 1-propanol. All filaments displayed increasing resistance upon exposure to the various alcohols combined with excellent reproducibility and recovery behavior. An attempt is made to identify the dominant mechanisms controlling the sensing process in a CB-containing immiscible polymer blend characterized by a double-continuity structure. The interphase region, its quantity, and continuity played a significant role in the liquid-transport process. Blend composition, filaments' extrusion temperature, and production shear rate level were considered as significant parameters determining the structure and the resultant sensing properties. (C) 2003 Wiley Periodicals, Inc.