Optimization of hot air welding process parameters for manufacturing textile transmission lines for e-textiles applications: Part I: Electro-conductive properties

Abstract

This paper presents optimization of the hot air welding process parameters for the formation of textile transmission lines and the electro-conductive properties of these manufactured transmission lines. A dedicated manufacturing set-up has been developed to allow a reliable and flexible textile signal transmission line at adequate conductivity. In order to manufacture textile transmission lines, different welding parameters with different conductive yarns and welding tapes were considered. Layered fabric structures consisting of textile transmission lines and fabrication tolerances were determined, as well as electro-conductive properties for welded samples. It was found that the choice of welding parameters, depending on the materials used for the formation of textile transmission lines, is extremely important for obtaining good electro-conductive properties. In addition, welding tapes and thermoplastic materials play an important role during the set-up of welding process parameters. Results statistically confirmed that welding tapes with conductive yarns can significantly cause a variety of changes in the signal qualities of welded textile transmission lines. The obtained results based on conductivity and signal-to-noise ratios are really promising for the manufacturing of e-textile transmission lines via hot air welding technology.

Thermal-Mechanical Sensory Properties of Hot-Air Welded Textile Transmission Lines

“…Th e bending rigidity of the welded textile transmission lines was evaluated on the face and back sides in warp and weft directions. Th e infl uence of welding tapes and conductive yarns on the bending rigidity of the welded specimens was confi rmed by previous research achievements [2][3][4]. Both the welding tapes and the conductive yarns increased the bending rigidity of welded transmission lines.…”

“…Additionally, the integrated welded textile transmission lines infl uence both the aesthetic and the comfort issues of the garment. Th e results of previous experimental works [3,4] show that the hot-air welding parameters such as air temperature and pressure, rollers velocity and pressure between rollers have not any signifi cant infl uence on mechanical stresses of the conductive yarns during the process. On the contrary, these parameters have aff ected drastically the comfort quality of the welded joint as well as the welded area visual appearance.…”

“…Furthermore, the bending rigidity of the embedded transmission lines depends signifi cantly on the welding parameters, the thermoplastic welding tape properties and the type of conductive yarns. Moreover, it has been shown that the constructed transmission lines have also adequate electrical properties at certain combinations of welding parameters [2,3]. In this study, the mechanical-thermal sensory properties of hot air welded e-textile transmission lines are investigated.…”

“…Th e quality of an e-textile welded transmission line depends on the welding parameters settings. Th e bond strength between a thermoplastic tape and a substrate fabric should be evaluated, followed by the testing of electrical properties such as the conductivity and the signal transmission loss of the welded conductive yarn [2,3]. Th e hot air welded transmission line must fulfi l the following requirements:…”

“…Th ere are diff erent textile technologies that have been used to embed conductive yarn on or into textile materials: weaving and knitting technologies, sewing and embroidery techniques, printing or coating electro-conductive polymers. In the last few years, the hot-air welding technology was introduced as a new technological approach for adhering conductive yarns onto the fabric surfaces to make e-textile transmission lines [2,3]. From the construction point of view, a hot air welded e-textile transmission line can be presented as a laminated fabric, composed of a thermoplastic tape, a conductive yarn and a fabric substrate (Figure 1).…”