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Integrating Electronics to Textiles by Ultrasonic Welding for Cable-Driven Applications for Smart Textiles
Sebastian Micus1,2, Sahar Golmohammadi Rostami3, Michael Haupt1
1German Institutes for Textile and Fiber Research Denkendorf (DITF), 73770 Denkendorf, Germany.
Materials (Basel, Switzerland)
|October 13, 2021
Summary
Ultrasonic welding creates durable connections between conductive textiles and wires, crucial for smart textiles. Despite a significant resistance increase after washing, mechanical strength remains largely intact, enabling practical applications.
Area of Science:
- Materials Science
- Textile Engineering
- Electrical Engineering
Background:
- Flexible textiles and rigid electronics integration is a challenge for smart textiles.
- Existing connection methods often lack durability, especially after washing.
Purpose of the Study:
- To investigate ultrasonic welding for reliable connections between conductive textiles and litz wires.
- To evaluate the electrical and mechanical performance of these connections after laundering.
Main Methods:
- Ultrasonic welding was used to join conductive textiles and litz wires.
- Samples underwent 15 and 30 wash-and-dry cycles.
- Contact resistance and peeling strength were measured.
- Connection properties were analyzed via microsections.
Main Results:
- Joint resistance increased over 300% due to silver-coated wire degradation after washing.
- Mechanical peeling strength decreased by approximately 20% after 15 cycles, with no further decrease after 30 cycles.
- Microsection analysis provided insights into connection integrity.
Conclusions:
- Ultrasonic welding is a promising technique for connecting textile electronics to conductive wires.
- This method offers a viable pathway for manufacturing robust smart textiles with improved washability.
