Thursday, March 28, 2024

Smart Fabrics: The Comfortable Way To Wear Your Tech

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has developed a method of making cotton textiles conductive by impregnating these with graphene based ink. Cotton is one of the most popular, durable and comfortable materials used for making clothing, and should ideally be used for e-textiles, too, if we want any kind of mass adoption.

To achieve this, the team has developed inks of chemically-modified graphene flakes that are more adhesive to cotton fibres than unmodified graphene. The ink is deposited on the fabric and then subjected to heat treatment for improving its conductivity. The modified graphene adheres to the cotton just like any other colour dye, which ensures that the fabric remains conductive even after several washes. The team demonstrated the effectiveness of the technique using a motion sensor based on the conductive cotton.

This method is expected to become quite popular in the future because graphene ink is chemically-compatible with cotton, unlike certain methods that require a polymer or plastic base. Also, it is less expensive and environment-friendly compared to metal based conductive inks, especially those using pure silver.

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Techie yarn.

Project Jacquard by Google proposes another method of weaving electronics into garments. It hopes to make it so easy that electronics can be woven into everyday garments! Their solution is based on conductive yarns, which combine thin, metallic alloys with natural and synthetic yarns like cotton, polyester or silk. The resulting Jacquard yarns are just like traditional yarns, and can be woven on any industrial loom. These yarns can be attached to discreet connectors and miniaturised circuits, to weave different kinds of technological applications into the dress. Some areas, for example, can be touch- and gesture-sensitive, while others can be sensor grids. Collected data can be wirelessly transmitted to mobile devices to provide varied services to the user.

The ability to manufacture the yarns and fabrics on standard looms used by mills across the world is, according to Google, the biggest benefit of this method. They have partnered with Levi’s to create interactive garments, which combine the traditional charm of denim with the benefits of technology.

One such product is Levi’s Commuter Trucker Jacket for urban bike commuters. When they are driving and cannot access their smartphones, wearers can control their mobile experience and connect to a variety of services such as music or maps, directly from the jacket.

A plasticky solution.

At K 2016 plastics trade fair, Covestro, one of the world’s leading polymer companies showcased luminous clothing made with freely-formable electronic systems, which are responsive to movements without losing their functionality. The garments use a flexible and formable film made of thermoplastic polyurethane (TPU) from Covestro.

TPU is the substrate for printed copper circuits, which are arranged in a meandering pattern and can, thus, also be bent and stretched. This technology is based on stretchable circuit board (SCB) technology developed earlier as part of European STELLA project, led by Fraunhofer Institute for Reliability and Microintegration (IZM) and Technical University of Berlin.

Owlet Smart Sock
Fig. 2: Owlet Smart Sock is a comfortable way to monitor babies (Image courtesy: Owlet)

According to the press release, the smart circuits are manufactured using an efficient, multi-stage process. The release states, “First, copper films are laminated onto polyurethane films. Printed circuits are produced in a subsequent structuring operation featuring highly effective adhesion. Coated films are then shaped as required using conventional thermoforming. Formable electronic systems can be directly laminated into textiles.”

Pretty and purposeful embroidery.

A team at The Ohio State University is developing a way of embroidering antennae and circuits into fabrics, with 0.1mm precision—a size ideal for integrating components like sensors and computer memory devices into clothing. Their method can be implemented using a typical tabletop sewing machine, except that it embroiders its patterns with fine silver metal wires. The thread has a diameter of 0.1mm and is made of seven filaments. Each filament has a core of copper, enamelled with pure silver.

The shape of the embroidery determines its functionality, say, frequency of operation in the case of an antenna. A broadband antenna, for example, comprises more than six small interlocking geometric shapes that form an intricate circle a few centimetres wide. Each piece of the circle transmits energy at a different frequency, so that these cover a broad spectrum of energies when working together, thereby enabling broadband capability for mobile phone and Internet access.

Other shapes serve other functions. There is a spiral-shaped antenna that helps improve mobile phone signal reception. Measuring 15.2cm (6-inch) across, this antenna can transmit signals at frequencies of 1GHz to 5GHz with near-perfect efficiency. Embroidered on the back of your dress, this spiral pattern could help boost the reception of your mobile device.

Screen printing tech onto fabrics.

Screen printing is another common method used to print designs on fabrics. Germany’s Fraunhofer Institute for Silicate Research hopes to use this process to bring tech into textiles.

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