The development of conductive yarns is growing rapidly due to their use in wearable electronic textiles for sensing, heating, and energy storage applications. These yarns can be integrated into fabrics using traditional textile fabrication techniques such as Embroidery, weaving, and Knitting. Their structural properties play a crucial role in the processability of fabrication techniques and atmospheric conditions, abrasion resistance, and sweat on the overall performance of the conductive yarn. However, an efficient evaluation of these properties of commercial conductive yarns remains limited. This work focuses on characterizing 15 commercially available conductive yarns with varying structures, materials, and fabrication techniques to evaluate structural properties, processability in embroidery, and abrasion resistance. Structural properties such as thick/thin places and hairiness were measured, along with their effects during embroidery. Changes in resistance due to abrasion were also evaluated to predict variations in electrical performance during wear. Additional tests were conducted in a climate chamber with temperature variations from 5 ℃ to 45 ℃ and a thermal manikin operating in dry and wet conditions to check the real-time effect during wearability. Highly twisted yarns with low hairiness demonstrated superior processability and resilience during embroidery and abrasion tests, maintaining stable electrical properties. In contrast, lower-twist yarns frequently experienced breakages and entanglements due to reduced structural integrity. Most materials displayed consistent resistance across varying conditions, ensuring reliability for wearable applications. However, one material exhibited significant variability, highlighting repeatability issues. Resistance changes during wet conditions depended on the sample's proximity to sweating pores. These findings provide a framework for selecting and characterizing conductive yarns, offering valuable insights for their integration into textile-based wearables and advancing the field of smart textiles.

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A Comprehensive Characterization of Commercial Conductive Yarns for Smart Textile Applications

  • Aftab Ahmed,
  • Mira Haberfellner,
  • Federica Morandi,
  • Thomas Preindl,
  • Andreas Pointner,
  • Anita Vogl,
  • Cohen Nitzan,
  • Andrea Gasparella,
  • Niko Münzenrieder,
  • Michael Haller

摘要

The development of conductive yarns is growing rapidly due to their use in wearable electronic textiles for sensing, heating, and energy storage applications. These yarns can be integrated into fabrics using traditional textile fabrication techniques such as Embroidery, weaving, and Knitting. Their structural properties play a crucial role in the processability of fabrication techniques and atmospheric conditions, abrasion resistance, and sweat on the overall performance of the conductive yarn. However, an efficient evaluation of these properties of commercial conductive yarns remains limited. This work focuses on characterizing 15 commercially available conductive yarns with varying structures, materials, and fabrication techniques to evaluate structural properties, processability in embroidery, and abrasion resistance. Structural properties such as thick/thin places and hairiness were measured, along with their effects during embroidery. Changes in resistance due to abrasion were also evaluated to predict variations in electrical performance during wear. Additional tests were conducted in a climate chamber with temperature variations from 5 ℃ to 45 ℃ and a thermal manikin operating in dry and wet conditions to check the real-time effect during wearability. Highly twisted yarns with low hairiness demonstrated superior processability and resilience during embroidery and abrasion tests, maintaining stable electrical properties. In contrast, lower-twist yarns frequently experienced breakages and entanglements due to reduced structural integrity. Most materials displayed consistent resistance across varying conditions, ensuring reliability for wearable applications. However, one material exhibited significant variability, highlighting repeatability issues. Resistance changes during wet conditions depended on the sample's proximity to sweating pores. These findings provide a framework for selecting and characterizing conductive yarns, offering valuable insights for their integration into textile-based wearables and advancing the field of smart textiles.