THE DEVELOPMENT OF THE WINTER JOGGING CAP

8/20/2019 THE DEVELOPMENT OF THE WINTER JOGGING CAP

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206International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882

Volume 3 Issue 2, May 2014

THE DEVELOPMENT OF THE WINTER JOGGING CAP

Engr. Muhammad Qamar Khan (Lecture National Textile University Karachi),

Muhammad Faizan, Sajida Hafeez, M. Sabeehul Hassan, Wazeer Husain, Muhammad Umer

AbstractThis research project represents an E-textile, a

wearable music system, which is a winter jogging cap.

This cap is designed to entertain the music lovers

during jogging in winters. Cap is equipped with MP3

circuit, rechargeable battery (3.7V) and headphones.

All circuits are embedded in knitted cap by conductive

thread. This cap provides comfort to user during

jogging. This project explains how all these electronic

components can be embedded in a cap making it easily

wearable

Keywords: Conductive yarn, MP3 circuit, spun core

yarn.

1. IntroductionThis section is divided into four main parts. First part

of this chapter is on E-Textiles. Second part of this

chapter is on Interactive electronic textile technologies

and third part is on Conductive threads embedded into

the garments, its uses and importance. Fourth part

consists of applications of E-Textiles. This chapter

also contains the images and E-Textile products.

1.1. E-TextilesIn the past, clothing integrated with electronic

components was only portrayed in science fiction.

Textile and apparel products containing electronic

components are no longer science fiction. Textile

based products are being developed which allow the

users to easily move with electronics components.

These textile products have potential to keep us

informed, connected and entertained. E textiles are

also called electro textiles or electronic textiles. E

textiles have evolved from the wearable computertechnology. U.S and Europe have introduced this

technology to the world. U.S Armed Forces and

Clothing companies have started to make products that

carry electronic systems. E-textiles have three different

generations from added on electronics to integrated

components with yarn.

First generation of wearable computer has system

which is wearable but it is not integrated into fabric.

These textiles are only body mounted. Second

generation of wearable computer has the system which

is wearable and the system is integrated on clothing

called surface mounted electronics. Third generation of

wearable computing systems have equal importance of

both clothing and electronic functions. Their functions

are compatible with each other. This generation has

opened the new path towards true electronic textiles. In

this generation wearable electronics blend into textile

materials. Electronic components are integrated in

textile yarn. Fabric having warp of silk thread and a

weft of silk thread wrapped with copper foil is an

example of this generation. It combines the functions

of both textile yarn and copper conductor. It is a hybrid

level. “SIGURD WAGNER “described that E-yarns in

which electronics are integrated at yarn level by

weaving, are used to make functional circuits.

A simple example of this is illustrated in figure 1.1.

Figure 1.1 Series connection of solar cells by weaving

In figure 1.1 Black segments are solar cells and grey

segments are insulating areas of fibers. Two groups Aand B are shown in figure 1.1. Fiber segments are

electrically connected on both sides in group A. Fiber

segments 1A through 4A are connected in series in

numerical order. Therefore fibers and voltage add must

be arranged such that each fiber segment has the same

photocurrent. Group A is connected with group B by

connecting the top contact of 4A to bottom contact of

4B in series, asshown in figure 1.1. [1]

1.2. Conductive yarnsJust two materials can be used for the production of

conductive yarns; these materials include conductiveand optical fibers. Electrically conductive textiles can

be produced by using conductive yarns. Conductive

yarns are produced by the wrapping of silver, copper

or gold foil on to non-conductive yarn/ filament to

provide conductive properties. It is believed that the

use of metallic yarns in decorative fabrics was

originated in India and is being used since mid-18th

century. One example in this field of technology is

metallic silk organza. This is a woven silk fabric.

Metallic silk organza is produced from two types of

yarns which include silk yarn as warp and silk as weftwrapped in thin capper foil or thread as shown in

figure 1.6. This thread is produced just like a cloth-

core telephone wire and is highly conductive (~0.1



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Ω/cm) i.e. very low resistance. In highly conductiveyarns silk core is used. Silk yarn is transformed into

this conductive yarn by copper threads. The tolerance

for high temperature and high tensile strength are

improved due to the physical properties of silk core

allowing it to be embroided or sewn on industrial

machinery without any damage to the machinery. Dueto these properties the metallic yarns are very capable

for mass production of interactive electronic textiles.

Figure 1.2 Micrograph of metallic silk organza

1.3. Musical GarmentIn market there are many types of products present that

are ranging from snowboards jackets to hoodies in

which music player are integrated and can be

controlled by using buttons. Some of the elucidations

take the hardware of music player and initiate them on

the sleeve or lapped inside by the use of E-textiles.“JuilHeo” back in 2001 also designed a garment,capable of playing music. He used sound synthetic

chip and Sound output element. For this purpose he

made holes in the garments for the buttons, where he

used switch empowered by a battery. Moisture proof

paper positioned between an inner surface of said non-

woven fabric pocket and rear surface of the printed

circuit board. [7]

1.4. Mp3 jacket with wireless remote controlAdding more into the previous work an mp3 jacket for

carrying mp3 player with wireless remote control was presented. “Nai Chung Tsai” used removableelectronics, so the jacket can be easily washable.

However, some like products have all parts assembled

permanently to the garment but have drawbacks.

Although the products are water proof, still they are

difficult to wash. It is also difficult to manage tracks in

the music player and you cannot change the music

player with a newer model. This garment has a first

pocket for carrying an mp3 player and the second

pocket for wireless remote control and jacket pullover

to hold earphones. [8]

1.5. Garment with speaker functionDar-Ming Chaiang& Jen-Yuh Jiang” invented garmentwith a speaker function in year 2009, in his article he

wrote that he used Garment body, bag and electrets

speaker. Bag is disposed on the garment body includes

a sound absorbing layer. The electrets speaker is

disposed on the garment and the sound absorbing layeris used to absorb the sound of the specific direction

therefore enhancing the acoustic quality.[10]

1.6 Cap for retaining an audio systemIn 2011, “Patrick T. Ryan” continued previous work and made a baseball styled cap that retains an

elasticized sleeve on the inside, from wall of the cap.

A potable audio player was inserted into the sleeve and

connected to pre-installed wiring and speaker system

that is integrated into the fabric seam of the cap. He

said that this cap provide with audio system, can be

worn and used in comfort with little or no limitation onthe physical activity of the wearer. [11]

Figure 1.3 Cap with music system

2. MaterialsIn this chapter design and materials used in smart cap

are discussed. Components used in smart cap are Mp3

player, Battery, Headphone and woven fabric. These

are integrated in a knitted cap by using conductive

thread and silicone sealant. Lock stitch machine is

used for stitching.

Knitted cap is selected for this project because it has

two layers and integrated circuit is invisible in this cap.

Winter caps are normally knitted and they completely

cover the ears. Characteristics of cap are described in

table 2.1.

Table 2.1 Characteristics of knitted cap

Wales per inch on face 9

Courses per inch on face 15

Wales per inch on back 7

Courses per inch on back 15

Machine type Flat machine

GSM 800



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Available woven fabric was used in cap to integrate

the circuit. Its properties are described in table 2.2.

Fabric is shown in figure 2.1.

Table 2.2 Characteristics of woven fabric

Weave type 3/1 Twill

GSM 219

Figure 2.1 Woven fabric stitched with conductive

thread

Available MP3 of smallest possible size in market was

used in Cap on the basis of comfort for wearing

purpose. Its characteristics are described in table 2.3

and it is shown in figure 2.2.

Table 2.3 Characteristics of MP3 Player

Company G2 Multimedia

Model G3-07

Width 2.79 cm

Length 4.06 cm

Height 1.27 cm

Figure 2.2 Music player (MP3)

Micro SD card of 2 Gb was used to store data asshown in figure 2.3. 200 Mp3 songs can be stored in it.

Figure 2.3 Micro SD card

Rechargeable Li-Ion battery of 3.7 volt was used. Thisbattery provides more operating time than the battery

provided with the music. Its characteristics are

described in table 2.4 and it is shown in figure 2.4.

Table 2.4 Characteristics of battery

Company Nokia

Length 5.3 cm

Width 3.4 cmHeight 0.45 cm

Figure 2.4 Battery

Small head phones of Sony, model MDR-Q140 were

used in cap which provided comforts as well as they

were invisible in cap. They are shown in figure 2.6.

Figure 2.5 Head phone

Conductive thread was used as a sewing thread to

transfer the electric signals from MP3 player to head

phones instead of wires. So that easy handling and

comfort can be provided. It was taken as bobbin thread

and in needle staple spun PC thread was used.

Conductive thread consisted of steel wires therefore it

cannot be used as needle thread. Wear and tear effect

can damage the conductive thread. Furthermore it was

needed to be straight without making any loop. That is

why it was used in bobbin. Conductive thread used in

this project is corespun. It is made up of steel core with

10 steel wires wrapped with a cotton cover. Its

resistivity is 1.114 (Ω/m) and conductivity is 0.897(S/m). It was measured by Ohammeter.Conductive

thread is shown in figure 2.6.



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Figure 2.6 Conductive thread

To laminate the conductive thread and to attach the

MP3 player, headphones with woven fabric silicone

sealant was used as shown in figure 3.4. Wires were

connected with conductive thread by soldering.

Silicone sealant is shown in figure 2.8.

Figure 2.7 Silicone sealant

Single needle lock stitch machine JUKI DDL 5550

was used for stitching. JUKI was chosen on the basisof their superior quality of sewing machines. Machine

is shown in figure 2.8.

Figure 2.8 Lock stitch machine

3. Design3.1.2 Construction of CircuitConductive thread was stitched using single needle

lock stitch machine (Class 301).

Figure 3.1 Stitch types 301

Whole circuit was made according to circuit diagram

as shown in figure 3.2. In stitching first of all

conductive thread was taken as bobbin thread and in

needle staple spun PC thread was used.Tension of

bobbin thread was more than the needle thread so that

conductive thread did not pass through fabric. Then

conductive thread stitched on woven fabric of 18inches length at 8 SPI as shown in figure 2.2. Length

of conductive thread from the center of fabric was 7

inches on both sides according to measured data.

Headphone input pin was attached at one end of

conductive thread by soldering similarly headphones

were attached at the other end. Circuit of MP3 with Li-

Ion battery (3.7V) was made then this MP3 circuit was

attached with Head phone Input pin. Circuit adjusted

in such a way that its charging port was laid at the

bottom of cap. So that battery can be charged. Whole

conductive thread was laminated with silicone sealant

to avoid moisture and short-circuit. All componentswere fixed on fabric with the help of silicone sealant.

Then this whole circuit was covered by stitching a

woven fabric on it. A piece of fabric was cut from the

face of headphones to avoid hindrance in voice quality.

Complete circuit is shown in figure 3.4.

Figure 3.2 Circuit diagram

Figure 3.3 Complete circuit

3.1.3 TestingAfter completion circuit was checked for a day and it

was fine. Signal transmission was proper.

3.1.4 Circuit Integration and positionAfter testing, this woven fabric with all electronic

components was stitched by hand stitching between

the two layers of cap on back side according to the

measured data. This MP3 circuit was stitched at center



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on back side of cap in such a way that SD card can be

removed from cap. One end of charging cable was

fixed with MP3 and the other end free outside of cap.

Then only portion of headphones was stitched at 7

inches from MP3 circuit on both sides in cap by hand

stitching. Folded the layers of cap and stitched them at

top of cap. In this way our product was ready for use.

Figure 3.4 Smart cap

4.1 Conclusion and Limitations

Such innovative smart cap should be manufactured tomaximize the chance of sustainability of the textile

sector in Pakistan as it’s a highly value added product.Smart cap is developed for entertainment. Volume of

music in cap was maintained in such a way that the

people in surrounding wound not be disturbed. The

prime use of this cap is to use it for weather protection

and for listening music during jogging. This is a better

choice than other available options i.e. mobile phone

and music player. The music player and mobile phones

are not user friendly as they have got the wires i.e.

Hands free which could compromise the comfort of

the user.

4.1.1 Operating ProcedureWear the smart cap in such a way that Mp3 player

remains on back side of head. Buttons are on back side

of cap, labeled by +, –, <,> and P. Buttons “+,-” areused to control the volume and “<, >” are used tomove on next or previous track. When you want to

listen music press the button P, similarly when you

want to pause it press the same button P. Similarly to

move on next or previous track and to increase or

decrease the volume, follow the same procedure on

buttons. To exchange the data plug USB connectorinto computer.

4.1.2 Limitations1. Battery should be recharge after 20 hours for one

hour.

2. Avoid washing, only dry-cleaning is

recommended.

References

[1] S. Wagner, “Electrotextiles: Concepts andchallenges,” International journal of high speed

electronics and systems, vol.12, no.2, pp. 391-

339,2002.

[2] Martin and Thomas et al, "Towards a design

framework for wearable electronic textiles." ISWC,

vol.3, 2003.

[3] S. Mann, “A First Step toward Personal

Imaging,”Wearable Computing, vol. 30, no. 2,

February 1997.

[4] D. Meoli, "Electronic textiles: Technologies,

Applications, Opportunities, andMarket potential," MS

thesis, North Carolina State University, Raleigh, May

2002.

[5] T.Mayplumlee and D. Meoli, A review of

Technologies, Interactive electronic textile

Development , vol.2, no.2, Spring 2002.

[6]Buechley L, "A Construction Kit for Electronic

Textiles," Wearable Computers, vol. 83, 90, pp. 11-14,

Oct. 2006.

[7] J.H. Seoul (KR), “Garment capable of outputting a

sound”, U.S. Patent 6192137, Feb 20, 2001

THE DEVELOPMENT OF THE WINTER JOGGING CAP

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