Transcript Slide 1

University of Mauritius
Faculty of Engineering
Department of Textile Technology
Postgraduate Research Degree
(MPhil/PhD)
Embedding Light and Sound in Textiles for Novel
Effects in Interior Design
Proposed by
G.K.Bahadur
February 2010
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Introduction
Textile materials such as woven, non-woven and knitted fabrics
are an excellent medium that can be used to integrate and accommodate
unobtrusive electronic devices.
For the first part of the research, much emphasis was placed on
the following:
• Finding different ways of embedding electronic wires and
microelectronics into textile fabrics in a discreet manner.
• Applying available conductivity threads and printing pastes on fabrics
without compromising its soft look and feel.
• Creating conductive printing paste that can be used on fabric.
• Developing innovative products such as the soft switch, E-Label and
the E-print for commercialised garments.
• Carry out fabric tests such as burn, colourfastness and washing tests
with the results recorded, analysed and compared.
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2.1 Literature Review
2.1.1 Related works
Research was carried out to find out the various products that have been
developed and commercialised over the past years. The ways these
products were constructed and integrated into textiles were also
recorded.
2.1.2 Commercial e-garments
Research was carried out to find out the various products that had been
developed and commercialised over the past years. Indeed many projects
had been undertaken to combine electronics with textile and nowadays
many fashion companies have commercialised electronic garments
which can be purchased at a reasonable price.
.
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2.1.3 Connecting Methods
In textile different ways to connect an electronic piece should be
considered. Clipping, stapling, gluing and snapping by using metal press
buttons were some methods that had been exploited in this project.
2.1.4 Power sources
The different power sources available had to be considered since
electronic textiles need some kind of electrical power to work. Several
types of portable power sources exist which vary in size and power.
2.1.5 Conductive Materials
One very important aspect to consider was conductive materials that
could easily be incorporated discretely in textiles. Some of these
materials were also used in realising some experimental works in this
project.
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2.1.6 Conductive Accessories in garments
Metal Accessories have been used in garments for many centuries.
They come in different forms and shapes and some are used for
specific functions whereas others are used for decorative purposes.
Most of the metals used, such as copper, aluminium and alloy, are
highly conductive.
2.1.7 LEDs
The definition of LED and the connection methods (parallel and in
series) were studied.
2.1.8 Resistors
The definition, function and the formula for determining the type of
resistor to use was considered.
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3.0 Methodology
3.1 Materials
Materials with good conductive properties, lightweight and thin were
sourced and different experiments were carried out. A preliminary
research was conducted and the main objective was to turn the
conductive materials into a printing paste in a very discrete manner
without compromising the drape and other properties of the fabric.
Different printing pastes were used and various tests were carried out.
Pastes such as expanding binder, high-density clear (H.D.C), normal
Binder and conductive printing paste were used.
3.1.1 Aluminium foil
Aluminium foil traditionally used in kitchen was used to carry
out the first set of experiments.
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3.1.2 Expanding Binder
Expanding Binder is a printing paste and when heat is applied, the
print expands, giving a 3DM effect.
3.1.3 High Density Clear (H.D.C)
High Density clear is another commercial paste, which is thick,
opaque and sticky. When heated at very high temperature, it turns into
flexible silicone like material.
3.1.4 Silicone Glue
Silicones are largely inert, man-made compounds with a wide variety
of forms and uses. Typically heat-resistant, nonstick, and rubberlike,
they are commonly used in cookware, medical applications, sealants,
adhesives, lubricants, and insulation.
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3.1.5 Latex
Latex is a material that is used in many types of garments and is
commonly seen in fetish fashion and costume designs (in movies).
They are made in polymers and rubbers and their applications are
endless. Latex comes in large sheet and in liquid form. The large sheet
can be cut in any garment shapes and glued together to make garments.
The liquid latex can be applied to any surface. It will permanently bond
to porous materials such as fabric and non porous materials can be used
as a mould. The liquid latex contains ammonia as a preservative agent.
It will cure at room temperature but is prone to adhere to itself which
can be solved by treating the surface.
3.1.6 Conductive Tape/ Fabrics: Electronylon Nickel
This versatile fabric is composed of a woven substrate of high quality
polyester taffeta fabric with a copper and nickel plating giving great8
conductivity. The production process is computer controlled to
Ensure consistency and the nickel gives the fabric a dull silver
appearance. It has exceptional electrical conductivity of 0 Ohms per
100 mm measured on a 25 mm wide strip (Data sheet available
from the Electrotextile Sample Pack, teaching resources, Middlesex
University).
3.1.7 Conductive Threads
This thread is sufficiently conductive and stronger as compared to
domestic poly/cotton thread and behaves like conventional cotton
and is made of over 100 strands each with nano-coating of silver. It
has an electrical resistance of just 4 Ohms per 100 mm.
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3.2 Experimental works
3.2.1 Expanding Binder and High Density Clear Paste (H.D.C.)
Target Set: Integrate LEDs in textile through prints.
Details: Expanding binder was used as a support to hold the LEDs
and the H.D.C was applied on the reverse side over the circuit as an
insulator. The circuit consisted of 5 LEDs and a resistor.
Target Achieved: Sample was connected to the power supply and lit
instantly. The integration of LEDs on the fabric surface was
successful although the fabric became a bit stiff because of the layer
of H.D.C. Alternative ways would be considered to solve this
problem.
3.2.2 Aluminium Foil and High Density Clear Paste
Target Set: Using kitchen Aluminium Foil in prints to conduct
electricity on textile
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Circuit sealed in H.D.C
Applying H.D.C on the back
Front print showing LEDs
and Expanding Binder
Illuminated Print
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Details: A layer of H.D.C. was applied on the fabric with a squeegee
via the screen-printing technique using a coarse mesh. Then, the
aluminium foil was cut, folded and stuck to the wet paste. The paste
was dried and a second coat of H.D.C was applied over the first coat
and dried. The Aluminium foil was sandwiched between the two coats
of H.D.C. The LEDs were inserted between the folds of the aluminium
foil.
Target Achieved: A thin transparent plastic print was obtained. The
drape, softness and weight of the fabric were not affected. This
technique could also be used to conduct Direct Current (DC) from one
point to another on a fabric.
3.2.3 Using crushed graphite to make conductive paste
Target Set: Creating conductive print using graphite that can be applied
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on fabric
Aluminum foil cut into shapes
Aluminum foil laid over wet H.D.C
Aluminum foil sealed in H.D.C
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Details: Graphite were crushed and spread over a printed layer of
wet H.D.C. H.D.C has excellent adhesive properties and is
commonly used in textile for flock and caviar printings.
Target Achieved: Paste was not successful. There were too many
gaps between each graphite particle.
3.2.4 Crushed aluminium flakes to make conductive paste
Target Set: Creating a cheap conductive print using aluminium
powder that can be applied on fabric
Details: Aluminium flakes were crushed and spread over a printed
layer of wet H.D.C.
Target Achieved: The printing paste failed to conduct. Carbon nano
particles were applied on fabric in the same manner and
the results were negative.
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Crushing
Graphite
Crushing
Aluminum Flake
Applying Graphite over wet H.D.C
Mixing Carbon Nano Particles with H.D.C
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3.2.5 Developing the Printed Electronic Soft Pad using woven
fabrics
3.2.5.1 Applying the Conductive Printing Paste on woven fabrics
Electrosperse D-112 was purchased from Five Star Technologies,
from the USA. It consists of components like Silver, Terpineol, Ethy
Cellulose and Glass Frit and is very conductive. It is not made to be
used on fabrics.
The best way to apply the paste on the fabric and avoid wastage was
to use stencil printing technique and to apply the paste either with a
brush or a sponge.
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3.2.5.2 Washing Tests with the Conductive Printing Paste
Target Set: Testing the resistance of the print after several wash.
Details: 3 prints with the Conductive Paste were printed on a piece
of fabric. Only 1 coat was applied on the first print, 2 coats on the
second print and 3 coats on the third print. All prints were cured.
Prior to washing, the resistance of each print was measured and
recorded. The fabric was hand washed and line dried. Then the fabric
was conditioned in an oven at 105 degrees Celsius for 4 hours. The
fabric was washed 3 times under the same procedure and each time
the resistance for each print was measured and recorded.
Target Achieved: The test carried out helped to determine the
washability and durability of the conductive paste.
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Rectangular Prints using Conductive Paste (Electrosperse D-112)
Soft switch
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3.2.5.3 Designing and making Printed Electronic Soft Pad
Target Set: The soft pad is similar to a board of electronic switches
but made in fabrics, and is soft, thin, light-weight and washable. Each
switch on the soft pad can be programmed to perform a particular task
such as lighting up or playing a tune.
Details: The soft switch consisting of two layers of fabrics was placed
on top of each other.
The circuit of the soft switch was designed and printed on the fabrics.
The two layers were then sewn together and tested.
Target Achieved: The soft switch was connected to a power supply
and each switch was further connected to a LED. The LED would only
light up when a slight pressure was applied on the switch. The soft
switch is very soft, light and with draping qualities. The soft switch
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opens up many avenues that can be further exploited.
3.2.6 Developing the Electronic Label (E-label)
3.2.6.1 Experimenting with High Density Clear
Target Set: E-label is a new and innovative invention and which can be
used in garments replacing the traditional leather, woven or plastic
labels that are used mainly in Jeans (on the waist belt) or on some
jackets.
Details: A circuit, consisting of LEDs and wires, was made and sealed
in high density clear paste and dried at very high temperature.
Target Achieved: The samples could be bent and twisted in any
direction without compromising the connection and it could be washed
and re-used again. The possibility of including the cell battery inside the
E-label with other types of Integrated Switches (IC) was further
explored. The only problem encountered was that after some time, the
H.D.C started to crack. Transparent silicone was used to replace the
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H.D.C
3.2.6.2 Experiencing with Transparent Silicone Glue
Target Set: Replacing the H.D.C with Transparent Silicone
Details: Transparent silicone was spread in an aluminium mould. A
circuit, consisting of flat square LEDs, electrical wires and 2 metal
clips, were inserted into the wet silicone paste. Connections were
soldered together. A logo was designed, printed on translucent paper
and thereafter inserted in the wet paste and left to dry overnight. After
drying, the silicone was easily removed from the mould. The thickness
of the E-label was 5 mm.
Target Achieved:
Problems encountered with samples:
• The connections broke at several points.
• The thickness of the e-label was 5 mm. It needed to be thinner.
• Smaller LEDs would be considered.
• Electrical wires were not appropriate and therefore using conductive
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threads was considered.
3.2.6.3 Experiencing with Transparent Silicone Glue
and using conductive thread
Target Set: Replacing the electrical wire with Conductive Thread and
reducing the thickness of the E-label from 5 mm to 3mm
Details: The Conductive Thread is a much better choice as the risk of
breaking is less. It can bend in any directions and the connections
can be made by simply tying knots instead of using solders. Three
ends of the conductive threads were twisted together. The circuit was
sealed in the silicone and left to dry.
Target Achieved: A new product, the E-Label was developed ready to
be inserted into any garment in numerous ways. The E-Label would
have to be connected to a power supply which would be inserted in the
garment. The circuit was protected by the layer of silicone and
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therefore could easily be washed.
Silicone sealed in an aluminum mould
Circuit can be twisted,
bent and wash without
Compromising the circuit
Circuit Sealed in Silicone
Circuit made of conductive threads and LEDS
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3.3 Conductive Threads
Conductive threads were purchased from the Internet and could be
bought in spool of 200 yards
3.3.1 Simple Experiments using the Conductive thread
Experiment 1- Measuring the resistance value of the Conductive
Thread along different length
Experiment 2- Measuring the resistance value of the Conductive
Thread when a knot was made along the length (to see whether tying
a knot would affect the conductivity)
Experiment 3- Measuring the resistance value of the Conductive
Thread when several ends of the conductive thread were used
together. All results were recorded in a table form.
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3.4 Knitting
Knitting is defined as a cloth manufacturing process in which needles
are used to form a series of interlocking loops from one or many yarns
or from a set of yarns (Hollen et al. 1979, p.183).
For this project two types of flat knitting machines had been used to
knit the samples:
• Industrial V-Beds Knitting Machines
• Domestic Knitting Machines (single bed only )
3.4.1 Knitting with the conductive thread
Five samples were knitted in different structures together with the
conductive thread. Different yarns, such as 100% Lamb Wool, 100%
Wool, 100% Cotton and a blend of 75% Rayon/ 25% PTT, were used
to knit the above samples.
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3.4.2 Laundry Test
The samples were washed at normal temperature (40 Degrees Celsius)
and were line dry at room temperature. Thereafter, the samples were
conditioned in an oven at 105 degrees Celsius for 4 hours. The
conductivity and size of each sample were measured and recorded.
3.4.3 Integrating LEDs into knitted samples
3.4.3.1 Sample 1: Ripples on a 3 X 7 Rib Structure (7 Gauge)
Target Set: Varying the knitting structure to make a wearable circuit.
Details: Ripples technique was used and knitted on a 7 gauge knitting
machine. The conductive thread was used with normal yarn and LEDs
were inserted into the knitted sample.
Target Achieved: The knitted sample was connected to a DC power
supply and the LEDs lit up creating some amazing effects.
Furthermore, the sample could be moved, twisted and bent without
compromising the connection.
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3.4.3.2 Sample 2: Ripples on a 4 X 4 Rib Structure (5 Gauge)
Target Set: Indentifying knitting structures that could be used to
incorporate and lit the LEDs using only the conductive threads.
Details: A different Ripples Structure was used and knitted on a 5
gauge knitting machine. The conductive thread was used with normal
yarn and LEDs were inserted into the knitted sample.
Target Achieved: The knitted sample was connected to a DC power
supply and the LEDs lit up. Furthermore the sample could be moved,
twisted, bent and this did not compromise the connection.
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3.4.4 Developing the Knitted Electronic Soft Pad
Target Set: Using knitting fabrics to make a soft pad without using
any electrical wires and switches. Two techniques were used namely
the Ripples Structure and the Single Bed Jersey.
Details: This ripple sample was considered because of the raised
surface created by the Ribs. The idea was to lay the ribs facing
downward on a flat conductive fabric (Single Bed Jersey). The ribs
prevented the conductive thread from touching the fabric underneath
unless pressure was applied.
Target Achieved: The Knitted Soft Pad was tested and the
result was very positive. Sample was very light, soft and could
easily be integrated in garments or furniture.
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3 X 7 Rib Ripple structure, Knitted
on a 7 gauge machine
4 X 4 Rib Ripple structure, knitted on a 5 gauge
Knitting machine
Knitted soft switch
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4.0 Further Works:
• Developing a cheap conductive printing paste for textiles using
powder aluminum and expanding binder.
• Incorporating conductive materials in woven fabrics through
different manipulating techniques without compromising the
look and feel of the fabric.
• Exploiting other manipulating techniques such as embroidery,
appliqué, etc.
• Incorporating the E-Label in garments
• Establishing illuminating prints in garments (E-Print).
• Using the soft switch in furniture and in garments to perform a
function.
• Developing products for home interior with some of the ideas
developed above.
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5.0 Problems Encountered:
• Difficult to work on research project during semesters.
• Materials are difficult to find especially on the local market.
• Materials are expensive.
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