Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design...
Transcript of Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design...
![Page 1: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/1.jpg)
AGILE SOLUTIONS FOR A CHANGING WORLD
Design Tool for Electronic Textile Clothing Systems
February 4th, 2014 Authors:
Jeremiah Slade – Infoscitex Corporation Justyna Teverovsky – Fabric Works, LLC Carole Winterhalter - U.S. Army NSRDEC
![Page 2: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/2.jpg)
2 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Background
• The incorporation of electrically conductive threads into woven or knit fabrics is the subject of many research projects and product developments.
• The ability to cut and sew such fabrics into complicated structures with large scale electrical functionality has remained elusive.
![Page 3: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/3.jpg)
3 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Background • Forming a functional network in textile articles
such as garments and shelters requires three types of connections: – Between external electronic devices and the fabric – Between warp and fill e-yarns in a single piece of fabric – Between e-yarns in two separate pieces of cut fabric at a seam
Connection into network
Connection inside network
Connection between two fabric
pieces
Fabric 1 Fabric 2
![Page 4: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/4.jpg)
4 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Selectively Enabled Wiring in textiles (SEWit)
![Page 5: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/5.jpg)
5 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
E-textile Fabric Development
• E-textile yarns, consisting of insulated copper wires wrapped around a cotton/nylon core yarn, were developed.
• The E-textile yarns were woven into the rip-stop portion of a Nylon/cotton fabric similar to that used in ACU garments.
![Page 6: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/6.jpg)
6 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Printing & Finishing • Samples of e-textile fabric were sent to
Bradford Printing and Finishing LLC for evaluation.
• These samples were inserted into a production run and subjected to normal printing and finishing processes including a Quarpel water repellent finish.
• Finished samples were evaluated for: – Electrical continuity: Passed – Enamel integrity: Passed – IR reflectance: Passed
Printed sample using desert sand wire with Quarpel water repellency finish
![Page 7: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/7.jpg)
7 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Connectorization and Integration • Welding and connectorization techniques were
developed for: – Connecting warp and fill e-yarns to create the desired network topology – Forming connections that bridge seam boundaries to form continuous
network paths between pattern pieces – Providing EMI shielding for network paths – Connecting external electronic devices with the fabric network
![Page 8: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/8.jpg)
8 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Networking Technologies • Demonstrated the feasibility of
transmitting power, analog audio-video signals, and 1000BaseT (Gigabit) Ethernet signals over SEWit e-textile networks. – Validated that transmission rates were
identical to conventional Ethernet cables
– Able to handle streaming video – Able to transmit across seams
• Investigated the feasibility of transmitting USB signals. – Requires shielding and impedance
matching
![Page 9: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/9.jpg)
9 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Prototype Garment Fabrication
• Prototype ACU jackets were fabricated using printed/finished fabrics.
• Electrical networks were created that routed power between battery packs and: – Electroluminescent Insignia Patches – Heating Pads
• Prototype backpacks with integrated solar energy harvesting capabilities were fabricated
![Page 10: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/10.jpg)
10 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Importance of Seams in E-textiles • Throughout our research it was observed that bridging seam
boundaries in a reliable manner required a detailed understanding of the seam construction, the e-textile pattern, and the welding parameters.
• Without this understanding connections may either not be formed or undesired connections may be formed in their place.
![Page 11: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/11.jpg)
11 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• The design of e-textile networks remains a time consuming process that relies on specialized engineers and trial and error.
• Realizing practical development cycles will require a new design tool that can streamline the process of: • designing the E-textile fabric, • making the pattern, • assembling the textile article, and • establishing the desired electrical networks.
E-textile Design Tool Motivation
![Page 12: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/12.jpg)
12 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• It is not practical to predict in advance exactly where connections
will occur so we are left with two options; – Determine the location where e-yarn interconnects will occur
between two pattern pieces once they have been sew together. OR – Make probabilistic predictions regarding the quantity and
distribution of interconnects that will form between any two pattern pieces.
• The first approach is valuable for certain prototyping scenarios but it does not provide any insight early in the design process.
• The second approach is more challenging to implement but results in a far more powerful tool that takes into account fabric, garment, and assembly parameters to arrive at an estimate of the number of interconnects that can be formed.
Development Strategy
![Page 13: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/13.jpg)
13 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Phase I Objectives & Approach
Pattern Piece 1
Pattern Piece 2
• Develop a mathematical model that could predict the variations in interconnect density that can occur along a seam.
• Determine the probability of forming cross-seam networks based on input parameters for the e-textile, garment and ultrasonic horn,
• Permit adjustment of these parameters as needed order to achieve the desired results.
• The observation that the intersection of e-yarn grids in a seam creates moiré patterns formed the foundation of our approach.
![Page 14: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/14.jpg)
14 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• Moiré patterns are interference pattern created when two grids are overlaid at an angle or when they have slightly different mesh sizes.
• The orientation and connection density of the lines that make up these patterns can be described using established equations.
Application of Moiré Pattern Models
![Page 15: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/15.jpg)
15 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Mathematical derivation of fringe parameters Using these equations the relationship between the e-yarn interconnections
forming the moiré fringes and the seam can be characterized.
![Page 16: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/16.jpg)
16 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• Investigated the iterative design and pattern making process used at the Natick Soldier Systems Center to transition from a design concept to the factory floor and how to best integrate our design tool into that process.
• Conducted a review of available pattern making software packages.
• Identified two basic design options; – Develop a plug-in module for an established closed-source
package (i.e. Gerber’s Accumark) – Develop a standalone tool that interfaces with established
software packages.
• Near-term development has focused on a standalone tool to reduce risk and demonstrate feasibility
Software Development Strategy
![Page 17: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/17.jpg)
17 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
System Inputs: •E-yarn spacing (T) •Angular shift (αs) •Seam angle (β) •Seam width (w) •Horn length (hd) •Seam type
Initial Model development
![Page 18: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/18.jpg)
18 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• For a defined set of geometric parameters (Seam width, horn size, etc.) the following weld parameters can be exported for all values of αs and β. – Nmin – Nmax – Navg – Std Dev
• Input Parameters: – T=0.25” – W=0.5” – Hd=0.5”
Data Export Function
![Page 19: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/19.jpg)
19 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
The number of available interconnects per unit area (D) can be seen to be proportional to the square of T. This provides us with a powerful means for
controlling the density of available interconnects in a specific region.
Moiré Parametric Study
0
10
20
30
40
50
60
70
-90 -60 -30 0 30 60 90
Inte
rcon
nect
Den
sity
(D)
Shift angle (αs)
T=0.125
T=0.25
T=0.5
![Page 20: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/20.jpg)
20 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Shift Angle / Seam Angle • E-yarn Spacing (T): 0.25-0.5” • Seam Width (w): 0.5” • Horn Width (hd): 0.5”
![Page 21: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/21.jpg)
21 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
• Model extension – Additional seam types – 2-D yarns – Weave patterns having
multiple length scales – Network Properties
Next Steps • Software Extension
– Real-time 3D plotting
• Software Interoperability – Patternmaking – Circuit layout
![Page 22: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/22.jpg)
22 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Acknowledgements
The authors would like to thank the U.S. Army Natick Soldier RD&E Center, and Ms. Carole
Winterhalter for supporting this research (Contract No. W911QY-12-P-0270).
![Page 23: Design Tool for Electronic Textile Clothing Systems...AGILE SOLUTIONS FOR A CHANGING WORLD Design Tool for Electronic Textile Clothing Systems February 4th, 2014 Authors: Jeremiah](https://reader033.fdocuments.us/reader033/viewer/2022060508/5f23bf43e9edeb0e3e7252c7/html5/thumbnails/23.jpg)
23 www.infoscitex.com
AGILE SOLUTIONS FOR A CHANGING WORLD
Contact Information: Mr. Jeremiah Slade
Infoscitex Corporation 303 Bear Hill Rd.
Waltham MA, 02451 Phone: (781) 419-6381
Email: [email protected]
Questions?