Interactive Electronic Textile

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Article Designation: Scholarly JTATMVolume 2, Issue 2, Spring 2002

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Volume 2, Issue 2, Spring 2002

INTERACTIVE ELECTRONIC TEXTILE DEVELOPMENT:A Review of Technol ogies

Dina Meoli and Traci May-PlumleeDepartment of Textile and Apparel, Technology and Management

North Carolina State UniversityEmails: [email protected] [email protected]

AB STRACT

Electronics may soon be integrated into textiles in our near environment. These "Interactive Electronic Textiles" (IETs) will benefit many traditional textile applications. Firms thatunderstand how to incorporate emerging IET technologies into their new product strategies willestablish and sustain financial and competitive advantages. Currently, product development

practitioners and academic researchers are investigating multiple technologies for their potentialin IET development. This research explored the emerging area of IETs by examining the potential

supporting technologies including their strengths and limitations.

KEYWORDS: Electronic textiles, smart fabrics, smart clothes, wearable computing, interactivetextiles

INTRODUCTIONThe electronics that facilitate our daily

pursuits and interactions may soon beintegrated into the textiles in all areas of ournear environment. These "InteractiveElectronic Textiles" (IETs) may find nichesin many traditional textile applications.Opportunities exist for IETs in fashion andindustrial apparel, residential andcommercial interior, military, medical andindustrial textile markets. IETs are being

developed for communication,entertainment, health and safety. IETtechnologies may one day integrate multipleelectronic devices directly into textile andapparel products using shared resourcesincreasing the mobility, comfort, andconvenience of such devices (Heerden,Mama, & Eves, 1999). For example,communication devices may be integrated

into products such as the garments inFigures 1 and 2 (Softswitch, 2001; Philips,

2001). Integrated compact disk players,MP3 players, electronic game panels, digitalcameras and video devices, and interactiveclub apparel that changes colors with the

beat of the music are all being developed(Heerden et. al.., 1999). Textile keypads on

Figure 1: Integrated Textile Keypad(Softswitch, 2001)
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


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Figure 5: Electronic Ski-Suit, (Philips,2001)

Figure 4: Electronic Sportswear Garment,Phili s 2001

a sleeve might be used to dial phonenumbers, type pager messages, and playmusic. Interior textiles for the home oroffice might control lighting, temperature, orother electronic devices. For example, atelevision remote control might be

integrated into the arm of a sofa, or a lightswitch integrated into a curtain (Figure 3).IETs can also be developed to detect

pressure and/or movement in sensitivemedical textiles, engineering fabrics, activesportswear, and automotive seats(Softswitch, 2001).IETs have the potential to improve currenthealthcare practices for monitoring

breathing, heart rate, stress levels, and bodytemperature. These IETs may increase

patients' mobility, provide addedconvenience, and improve the quality of lifefor those with health problems or disabilities(Havich, 1999). High-performanceelectronic sportswear can track, and enhance

performance for a workout at the gym or forextreme sporting activities. The garment inFigure 4 features integrated fabric sensors tomonitor and display pulse, blood pressure,time, distance, speed, and calories. Suchsensors can also record arm action forimproving golf or tennis swings, bodytemperature, or can be used to developworkout regimes (Roberts, 2000).

Textiles integrated with sensory devicesdriven by a Global Positioning System(GPS) can detect a users exact locationanytime and in any weather (The

Aerospace, 2001). IETs with integratedGPS, such as the ski suit in Figure 5,enhance safety by quickly locating thewearer and allowing the suit to be heated.Parents can easily keep track of a childs

Figure 2: Sleeve Integrated CommunicationDevice, (Philips, 2001)

Figure 3: (Left) Remote Control (Right)Li ht Switch Softswitch, 2001


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Figure 6: ElectronicChildren'sGarments, (Philips,2001

location with garments containing integratedGPS (Figure 6) (Foster, 1999). GPS canalso provide added safety for emergency

personnel by facilitating offsite monitoringof vitals (Havich, 1999).

Textile firms that understand how toincorporate emerging IET technologies intotheir new product strategies will establishand sustain financial and competitiveadvantages. Wearable electronics arealready finding many opportunities in non-textile products such as implantedmicrochips and digital jewelry (Rajkhowa,2000). Progressive apparel firms aredeveloping strategic partnerships andexploring ways to market interactive apparel("Smart Clothes", 2002). This researchinvestigated the emerging area of IETs byexamining the technologies currently beingscrutinized for IET development.

CONDUCTIVE TECHNOLOGIESThe area of IETs has emerged from thewearable computing arena. Many of thewearable computing devices developed todate are cumbersome and awkward (Figure7), typically strapped or carried on the body.But, textile-based wearable electronics thatallow interactive touch, voice, and body heatactivation are being developed. The currentversions use integrated wiring and carryingdevices that add bulk and weight to thegarments making them uncomfortable andimpractical for daily use. These items arealso expensive and present issues relating tomaintaince, flexibility, and user safety

(Mann, 1998). The first wired electronic

apparel line to be marketed to consumersincluded four jackets, such as the Mooring(Figure 8). In these jackets, concealed innerwiring connects a mobile phone and MP3

player, built-in speakers, a microphone and a

Figure 8: (Left) Jacket by Levi Strauss & PhilipsResearch Laboratories, (Right) IntegratedCommunications System (Izarek, 2000)

Figure 7: "Wearable" computing devices


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display. The devices and the control padcan be disconnected for garment laundering,however the inner wiring and connectorscannot be removed limiting maintenanceoptions. These jackets also have verylimited compatibility and upgrading options(Izarek, 2000).

To develop more appealing wearableelectronics, conductive materials are beingused to transform traditional textile andapparel products into lightweight, wirelesswearable computing devices. Materials,such as metallic and optical fibers,conductive threads, yarns, fabrics, coatingsand inks are being used to supplyconductivity and create wireless textilecircuitry.

One way IETs can be created is by usingminute electrically conductive fibers. Thesefibers have historically been used inindustrial applications to control static and

provide electromagnetic interferenceshielding. They can be produced in filamentor staple lengths and can be spun withtraditional non-conductive fibers to createyarns that possess varying degrees ofconductivity (Figure 9). The yarns can beused to develop wash and wear conductive

fabrics that look and feel like a normalfabric (Electro Textiles, 1999). Conductivefibers can be classified into two generalcategories, those that are naturallyconductive and those that are speciallytreated to create conductivity (Lennox-Kerr,1990). Naturally conductive fibers ormetallic fibers are developed from

electrically conductive metals such asferrous alloys, nickel, stainless steel,titanium, aluminum, copper, and carbon.Metal fibers are very thin metal filaments,with diameters ranging from 1 to 80 microns(m), or .001 to .080 millimeters. They aretypically produced by a bundle-drawing

process or by a shaving process duringwhich the fibers are shaved off the edge ofthin metal sheeting. Though highlyconductive, metallic fibers are expensiveand their brittle characteristics can damagespinning machinery over time. In addition,they are heavier than most textile fibersmaking homogeneous blends difficult to

produce (Bekaert, 2001).

Electrically conductive fibers can also be produced by coating fibers with metals,galvanic substances or metallic salts likecopper sulfide and copper iodide. Metallicfiber coatings produce highly conductivefibers, however adhesion and corrosionresistance can present problems. Galvaniccoatings provide relatively highconductivity, but can only be applied toconductive substrates such as graphite andcarbon fibers. Due to manufacturingcomplexity and expense, galvanic coatingsare usually not used for textiles. A variety

of fibers can be coated with metallic saltsusing traditional textile machinery. Thesecoatings can only achieve low conductivitiesthat are further reduced during laundering.Altering coating procedures can improvethese limitations (Lennox-Kerr, 1990).

Optical or glass fibers, about 120 microns indiameter, can also be used to produce IETs.Optical fibers are used in composites,telecommunications, local area networks(LAN's), cable TV, closed circuit TV,

optical fiber sensors, and conductive textilesto carry signals in the form of pulses of light(Bell College, 1997). They are developed

by drawing molten glass through bushings,creating a filament. Though optical fibersoffer excellent strength and sunlightresistance, they are relatively stiff

possessing poor flexibility, drapability andabrasion resistance (Owens Corning, 2001).

Figure 9: Stainless Steel and Polyester Yarn


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Optical and electrically conductive fiberswere used to develop a Smart Shirt thatmonitors the wearer's heart rate, EKG,respiration, temperature, and other vitalsigns. The textile platform (Figure 10)collects data from various parts of thewearer's body and routes it to a smalltransceiver device attached to the shirt(Georgia Institute, 2000). Collected data is

processed and transmitted via the Internetfor biomedical monitoring and wearablecomputing applications (SensatexIncorporated, 2001).

Metallic yarns, created by wrapping a non-conductive yarn with a metallic copper,silver, or gold foil, can also be used to

produce electrically conductive textiles(Post, Orth, Russo, & Gershenfeld, 2000).One example of this technology uses ametallic organza woven with a plain silkwarp yarn and a silk yarn wrapped withcopper in the weft direction (Figure 11).The silk provides tensile strength and

tolerance forhigh

temperatures.This allows themetallic organzafabric to be sewnor embroideredon industrialmachinery (Orth& Post, 1997).

Conductivethreads, typically finer and stronger thatconductive yarns, can be machine sewn todevelop IETs. Their conductivity can be

controlled through stitch placement.Embroidering with conductive threads offersadvantages for IET development includingthe abilities to stitch multiple layers of fabric

in one step and to precisely specify circuitlayout with CAD (Post et al., 2000). Thekeyboard in Figure 12 was embroidered witha stainless steel and polyester compositethread. It is highly responsive to touchallowing the user to play notes, chords, andrhythms ("Musical Jacket Project," 2001).

Conductive coatings can transformsubstrates into electrically conductivematerials without significantly altering theexisting substrate properties. They can beapplied to the surface of fibers, yarns orfabrics through processes includingelectroless plating, evaporative deposition,sputtering, coating with a conductive

polymer, filling or loading fibers, andcarbonizing. Electroless plating involvesimmersing a textile in an electroless platingsolution where chemical reactions form thetypically nickel or cooper coating on thetextile. Electroless plating produces auniform electrically conductive coating, butis expensive (Vaskelis, 1991). Inevaporative deposition, a textile substrate isexposed to vaporized metal, typicallyaluminum, that condenses on the surface andforms a coating. This process can produce awide range of coating thickness for varyinglevels of conductivity, and is beinginvestigated for development of relativelythin, highly conductive evaporative coatingsfor highly conductive yet lightweight fabrics

Optical Fibers

Micro hone

Sensor

Transceiver

Figure 10: "Smart Shirt" Textile PlatformGeor ia Institute, 2000

Figure 11: Micrographof Metallic SilkOrganza (Orth, 1997)

Figure 12: Embroidered Fabric Keypad("Musical Jacket Project," 2001)


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(Smith, 1988). In the sputtering process, thecoating material is ejected atom by atomonto the surface of a textile substrate,creating a thin coating. Sputtering canachieve a uniform coating with goodadhesion, but is only about 10% of the speedof evaporative deposition, and isconsequently quite costly (Siefert, 1993).Textile substrates can be coated with aconductive polymer such as polyaniline and

polypyrole to achieve conductivity (Kahn,Kimbrell, Fowler, & Barry 1993).Presently, such polymers are used forconductive and anti-static coatings on yarns,fabrics and films. These polymer coatingsare more conductive than metal and haveexcellent adhesion and non-corrosive

properties, but they are difficult to processusing conventional methods ("ElectroactivePolymers," 1999). Filling or loading textilefibers with carbon or metallic salts such ascopper sulfide also creates a conductivecoating. Carbon-loaded fibers possess goodconductivity and are easily processed inconventional textile systems, while metallic-salt loaded fibers have comparatively lowerconductivity (Heisey & Wightman, 1993).Finally, carbonizing involves processing thetextile in a carbonization furnace at 1000 oCto create an electrically conductive textile.This process has been used to create agarment that reacts to changes intemperature, controlling body temperaturewithin 0.5 oC. (Lennox-Kerr, 2000).

Conductive ink technology offers anotheralternative for IET development. Addingmetals such as carbon, copper, silver, nickel,and gold to traditional printing inks createsconductive inks that can be printed ontovarious substrates to create electricallyactive patterns. Conductive ink technology,originally developed for smart cards or

printed circuit boards, has been used invarious market applications includingcomputers, communications, automotive,industrial electronics, instrumentation,government/military, consumer (e.g. homethermostats) (US Market, 1998). Use ofconductive inks for flexible printed circuits

has increased due to cost saving overtraditional production techniques,improvement in durability, reliability andcircuit speeds and reduction in circuit sizes(Cahill, 1998). A technology for usingconductive inks to make interactive talking

products such as T-shirts, sound books, packaging, and wallpaper has been patented.The inks withstand bending and launderingwithout losing conductivity (Colortronics,2000). Conductive inks are currently appliedwith technologies such as gravure,flexographic, and rotary screen-printing thatuse rollers to print the inks onto substrates.These methods are both labor and capitalintensive, and may create long productiondelays when designs are changed over(Miles, 1994). The benefits offered bydigital printing technologies have promptedmany conductive ink developers toexperiment with digitally printing them ontotextile substrates. Digital printing eliminatesmany of the intermediary steps associatedwith traditional printing methods offeringgreater design versatility and productionflexibility. Additionally, digital files can besent electronically to other locations for

printing (Rehg, 1994). Digital printing ofconductive inks presents several challengesincluding pre- and post- treatments,

developing the appropriate ink viscosity,achieving the conductivity through constantagitation of the ink reservoir, delivery ofappropriate ink quantities, and proper drying(Armbruster, Borgenstein & Emil, 2001).

ENABLING TECHNOLOGIESThe technologies previously discussed areused to create textiles that have the ability toconduct electricity. Additional componentsincluding input and output devices, sensors,and power supplies are necessary to create

an IET. Input devices including keyboardsand speech and handwriting recognitionsystems are some options being explored forIET data entry. The output technologiesunder investigation include Cathode RayTubes (CRTs), Liquid Crystal Displays(LCDs), mirror displays and flexible lightemitting displays (Ducatel, 2000). Sensorsare small electronic devices that can receive


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and respond to stimuli enabling electronictextile functions to be related to the user.They can either be attached to or integratedinto a textile substrate (Farringdon, 2001).Power supply technologies, typically

batteries, provide the electrical power foractivating the components in an electronictextile. In recent years batteries have notonly become smaller and more powerful,some varieties are mechanically flexible,water-resistant (washable), and lower cost(Hahn & Reichl, 1999). One type isfabricated by screen printing silver-oxide

based paste on a substrate to yield batteryonly 120-microns (m) thick. Solar energyand energy created by the human body arealso being studied as sources of electrical

power for IETs (Hahn & Reichl, 1999).

Molecule-sized computers, sensors, andelectronic devices can be directly integratedinto textiles using nanotechnology(McGuinness, 1997).Microelectromechanical Systems (MEMS),also known as micromachines,nanomachines, or transducers, are less thanone square millimeter in size and usuallyconsist of mechanical microstructures,microsensors, microactuators, andelectronics integrated into a single chip.

MEMS could potentially provide smart-sensors for IETs (Holme, 2000).

COMPONENT INTEGRATIONRegardless of the conductive materials usedto develop an electronic textile, theelectronic components and power supplymust be integrated into the textile to createan IET. Soldering, bonding, stapling, and

joining are some of the methods being usedto accomplish electronic component and

power supply integration (Post et al., 2000).

Soldering involves mounting thecomponents directly onto the surface of atextile. Soldering achieves good electricalcontact, but the toxicity of solderedcomponents makes them unsuitable forapplications where they could come incontact with a user's body. Furthermore,fabric flexibility is often compromised,making soldering unfavorable for many

apparel applications. Bonding involvesusing conductive adhesives to embedcomponents into textile substrates. Non-toxic, highly conductive, highly durable, andmoderately flexible conductive adhesivescan potentially be used to bond rigidcomponents with flexible textile substrates.Components can also be stapled intoconductive stitched circuits to createelectronic textile circuitry. When thesubstrate flexes or bends the conductivetrace is free to move. However, such flexingstretches the pins that attach the componentto the substrate, accelerating wear and tearon the textile (Post et al., 2000). Joininginvolves attaching an electronic component'sthread frame directly to a stitched fabriccircuit. Threads leading out of the electroniccomponent can be stitched, punched, orwoven through the substrate constraining thecomponents to specific locations andallowing the conductive threads to be evenly

balanced (Post et al., 2000).

WIRELESS TECHNOLOGIESIn order to simplify the connections betweenelectronic devices, new wirelesstechnologies may be used. Commonly usedwireless devices, such as cellular phones and

pagers, use radio frequency local areanetworks [RF LAN's], but the limited radiofrequency spectrum is quickly being filled.Personal Area Networks (PAN's) provide analternative. PAN's enable electronic devicesto exchange digital information, power, andcontrol signals within the users personalspace (Zimmerman, 1996). PANs work byusing the natural electrical conductivity ofthe human body to pass incredibly smallamounts of current through the body. Thesecurrents can transmit data at speeds

equivalent to a 2400-baud modem, orapproximately 400,000 bits per second. Thecurrent used is less then the body's naturalcurrents, measuring one-billionth of an ampor one nanoamp. By comparison, theelectrical field created when a comb is

passed through hair is 1,000 times greaterthan the current used by PAN technology("Personal Area Networks," 1996). Modular


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devices supporting shared functions can beconnected with a PAN.

A new radio frequency standard enableselectronic equipment to form a network andcommunicate automatically without wires,cables, or any direct action from a user("How Bluetooth," 2001). This wirelesstechnology has created some public concern

because radio frequency (RF) fields broadcast in all directions and therefore areemitted into the body. To overcome thishealth concern, researchers are exploringoptions such as the Fabric Area Network(FAN) to restrict the range of the RF fieldsto the surface of the textile. FANs usewireless RF communication links, but thecommunication fields are restricted to thesurface of a textile eliminating emission intothe body (Hum, 2001).

RELATED CHALLENGESIn order for IETs to succeed in the consumermarket, they will need to possess easy carecharacteristics, and maintain theirconductivity through repeated care cycles.Wearable IETs must not be damaged byconstant motions and stress from bodymovements, static from fabrics, perspiration,and body heat. Rapidly changing

technologies make upgradability another keyissue. Today, radiation and electrocution aresmall threats to our health and safety, butuse of IETs may increase these threats.IETs worn by children demand strongstructures lacking small detachable parts.Environmental characteristics such as rain,humidity, extreme temperature fluctuations,and other inclement weather may createsafety hazards.

IET products support a societywhere home, office, transportation, clothing

and even our bodies will be seamlesslyconnected by wireless networks, raising

personal privacy and security concerns(Thieme, 1999). The right to personal

privacy and security are universalexpectations. In a recent study, seventy-five

percent of those interviewed felt personal privacy and security were very importantsocial issues in today's society (Coleman,

1997). Advancing technology and theunrestricted exchange of electronicinformation justifies increasing concerns. Asnew technologies that involve large amountsof personal information become more

predominant, users will no doubt beinterested in protecting their personal

privacy and security (Garfinkel, 2000). Wemay soon have a greater capacity to monitorindividuals without their knowledge,develop more heinous weapon systems, oreliminate the need for human contact inmany activities (Johnson, 1991).

CONCLUSIONThe volume of available literature on eachtechnology could suggest that productdevelopment efforts are advancing morerapidly for conductive thread, metallic fiber,and optical fiber technologies. Challengesnoted in developing flexible electroniccircuits from conductive coatings and inkscould explain slower development in thosetechnologies. Though not among thetechnologies dominating the literature, therewere some indications that conductive

polymer fibers and conductive polymermaterials are also being studied for IETdevelopment. These materials offeradvantages in that they can be developed

according to specific requirements, and mayovercome many of the limitations of metal-

based solutions.

Health monitoring and feedback seem to beimportant foci of development efforts,

perhaps due to the abundance of militaryfunding supporting work in this area.However, entertainment applications may bean equally important application area

because these IETs need not be as robust or powerful as those for health, safety, and

military applications.

Because IETs will incorporate many kindsof electronic devices into their structures,some level of skill will be required tooperate and use them. The ease of use is animportant criteria for product developmentand some IET products may require a levelof product knowledge for operation that


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could affect market success. The industrywill need to educate consumers on productusage and possibly offer post-purchase

product assistance to make these productsappealing.

Upgrading and compatibility options, retail price points, and care and maintenancerequirements are all important to the marketappeal of IET products. Consumer appealwill rely heavily on the ability of IET

products to be easily cared for andmaintained, and these issues need to beaddressed in product development. As IETsenter the market they are likely to beexpensive at first and, as technology

progresses and production processes are perfected, prices will decline. Updated andadvanced product versions appear on themarket so quickly that many consumersconsider compatibility and upgradability inthe purchase decision. IETs will need to becompatible with various types and brands ofelectronics, and will need to be upgradeableto achieve market success.

Though product development is still facedwith many challenges, the future for IETslooks promising. Research and developmentefforts will enable product developers to

overcome current challenges to advancingIET development. Research to support IETdevelopment is being conducted inuniversities (DARPA, 2001; Holme, 2000;Brunel University, 2001; Fiber Materials,2001), businesses ("Smart Clothes," 2002;Orth, Post, Russo & Gershenfeld, 2001), andgovernment supported agencies (El-Sherif,2000). Growing consumer interest inmobile, convenient electronic devices willfuel the demand for IET products.

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Author Information:Dina Meoli - [email protected] Traci May-Plumlee - [email protected] Department of Textile and Apparel,Technology and Management

North Carolina State University
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

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