Conductive fabrics for heating applications

By coating textiles with electrically conductive organic polymers, we are able to produce functional, intelligent fabrics. These fabrics can be utilised in applications such as gas sensors, actuators, electromagnetic shielding, radar absorption, selected frequency filtering in indoor wireless applications, and heating applications where vital parts of the body can be heated without embedding any wiring through the fabric.

Heat generation in fabrics coated with the conductive polymer polypyrrole was investigated. The fabrics were coated by chemical synthesis methods by oxidizing the pyrrole monomer in the presence of the fabric substrate. Ferric chloride was selected as the oxidizing agent and anthraquinone-2-sulfonic acid (AQSA) sodium salt monohydrate as the dopant.

Conductive fabrics were characterized by resistivity measurements, scanning electron microscopy, thermal imaging, current transmission over a period of time and calculations of power density per unit area. Effects of reaction conditions on the electrical properties and heat generated are presented. Polypyrrole coated fabrics were stable and possessed high electrical conductivity. Resistivity values ranged from 100-500 ohms/square depending on the reaction parameters. When subjected to a constant voltage of 24V, the polypyrrole coated polyester-Lycra® fabric doped with AQSA reached a maximum temperature of 42°C and a power density per unit area of 430 W/m² was achieved.

Objective assessment of pilling of nonwoven fabrics using the two dimensional discrete wavelet transform

Fabric pilling is a serious problem for the apparel industry, causing an unsightly appearance and premature wear. Woolen products are particularly prone to pilling. Recently, a process for production of woolen nonwoven apparel fabrics has been commercialized in Australia, and may lead to new markets for Australian wool. However, the success of such nonwoven fabrics will partly rely on their propensity to pill. A key element in the control of fabric pilling is the evaluation of resistance to pilling by testing. Resistance to pilling is normally tested in the laboratory by processes that simulate accelerated wear, followed by a manual assessment of the degree of pilling by an expert based on a visual comparison of the sample to a set of test images. To bring more objectivity into the pilling rating process, a number of automated systems based on image analysis have been developed. The authors previously proposed a new method of image analysis based on the two-dimensional discrete wavelet transform to objectively measure the pilling intensity for woven fabrics. This paper presents preliminary work in extending this method to nonwoven fabrics.

Improvement of adhesion of conductive polypyrrole coating on wool and polyester fabrics using atmospheric plasma treatment

In this paper wool and polyester fabrics were pretreated with atmospheric plasma glow discharge (APGD) to improve the ability of the substrate to bond with anthraquinone-2-sulfonic acid doped conducting polypyrrole coating. A range of APGD gas mixtures and treatment times were investigated. APGD treated fabrics were tested for surface contact angle, wettability and surface energy change. Effect of the plasma treatment on the binding strength was analyzed by studying abrasion resistance, surface resistivity and reflectance. Investigations showed that treated fabrics exhibited better hydrophilicity and increased surface energy. Surface treatment by an APGD gas mixture of 95% helium/5% nitrogen yielded the best results with respect to coating uniformity, abrasion resistance and conductivity.

Objective pilling evaluation of wool fabrics

An objective pilling evaluation method based on the multi-scale two-dimensional dual-tree complex wavelet transform and linear discriminant function of Bayes' Rule was developed. The surface fuzz and pills are identified from the high-frequency noise, fabric textures, fabric surface unevenness, and illuminative variation of a pilled fabric image by the two-dimensional dual-tree complex wavelet decomposition and reconstruction. The energies of the reconstructed subimages in six spatial orientations (±15º, ±45º, ±75º) are calculated as the elements of the pilling feature vector, whose dimension is reduced by principal component analysis. A linear discriminant function of Bayes' Rule was used as a classifier to establish classification rules among the five pilling grades. A new pilled sample with the same physical construction can then be automatically assigned to one of the five pilling grades by the classification rules. A general evaluation of the proposed method was conducted using the SM50 woven, non-woven, and SM54 knitted standard pilling test image sets. The results suggest that the new method can successfully establish classification rules among the five pilling grade groups for each of the three standard pilling test image sets and should be applicable to practical objective pilling evaluation.

Photochromic wool fabrics from a hybrid silica coating

In this work, a photochromic wool fabric has been prepared by applying a photochromic-dye hybrid silica sol-gel onto the surface of fabric. The photochromic fabric was found to have a very quick optical response. Two types of silica were used as the matrix material, and the type of silica had a small effect only on the photochromic performance, the fabric washing fastness, and water contact angle, but affected the fabric handle property considerably. The silica from a precursor containing a long alkyl chain showed very little influence on the fabric handle and better photochromic performance than that containing a phenyl group.

Conductive poly(α,ω-bis(3-pyrrolyl)alkanes)-coated wool fabrics

Cross-linked poly(α,ω-bis(3-pyrrolyl)alkanes) were directly applied to woven wool substrates by either chemical, vapour or mist polymerization methods. Choice of dopant could greatly improve the surface resistance. The optimum coating on textiles with the lowest surface resistance, highest colour-fastness and stability was achieved using a mist polymerization method with 1,8-bis(pyrrolyl)octane, iron(III) chloride (FeCl₃) as the oxidant and p-toluene sulfonic acid sodium salt (pTSA) as the dopant.

Effect of weight reduction pre-treatment on the electrical and thermal properties of polypyrrole coated woven polyester fabrics

Weight reduction increased the amount of deposited polypyrrole (PPy) on the polyester (PET) fiber surface, leading to a considerable decrease in electrical resistance and improved heat generation capacity for the PPy coated PET fabrics. Application of dc voltages to an insulated roll of PPy-coated fabric increased the temperature to about 90 °C. This showed the suitability of these fabrics for heating applications. The optimum PPy deposition of about 2.8% was obtained in samples weight reduced by aqueous sodium hydroxide treatment. AFM images revealed a smooth surface morphology of the untreated fiber whereas the treated fiber had a high surface roughness.

Conducting polymer coated fabrics for potential applications in microwave frequencies : a study of electromagnetic properties

The microwave reflection, transmission and complex permittivity of paratoluene-2-sulfonic acid doped conducting polypyrrole (PPy/pTSA) coated Nylon-Lycra textiles in the 1-18 GHz frequency were investigated. The real part of permittivity increased with polymerization time and dopant concentration, reaching a plateau at certain dopant concentration and polymerization time. The imaginary part of permittivity showed a frequency dependent change throughout the tested range. All the samples had higher values of absorption than reflection. The total electromagnetic shielding effectiveness exceeded 80% for the highly pTSA doped samples coated for 3 hours.

Thermal conductivity studies on wool fabrics with conductive coatings

Methods of improving the thermal conductivity of wool fabrics have been investigated. Thermal conductivity measurement techniques, influence of synthesis parameters on the thermal conductivity of polypyrrole (PPy)-coated wool fabrics, and the relationship between electrical conductivity and thermal conductivity of PPy-coated wool fabrics are presented. An improvement in thermal conductivity was observed when fabrics were coated with the PPy. The thermal conductivity increased with the increase of pyrrole concentration and synthesis time. Anthraquinone-2-sulfonic acid and ferric chloride showed an optimal concentration for their influence on the thermal conductivity of the coated fabric. The improvement of thermal conductivity of wool fabrics is also investigated by Physical Vapor Deposition technique.