Manufacturing Techniques of IOT Hybrid Fiber Materials: History
View Latest Version
Please note this is an old version of this entry, which may differ significantly from the current revision.
Contributor:
Hye Ree Han

The fabrication of smart fabrics can be divided into coating and lamination processes. Coating methods include dip, knife or blade, air knife, metering rod, transfer, roll, paste dot, and powder. Laminating methods include flame, wet adhesive, hot melt, dry heat, and ultrasonic. Flame lamination is a process in which a prepared thin thermoplastic foam sheet is passed over an open flame to generate a thin layer of a molten polymer. Polyurethane foam (PUF) is the most frequently used foam. Wet adhesives used in the laminating process are either water- or solvent-based. They are applied to the substrate surface in liquid form using conventional coating methods, such as gravure roll coating, spraying, roll coating, and knife coating. Then, the adhesive-coated web is bonded with other substrates under pressure and dried or cured in an oven.

  • hybrid fiber material
  • electrical conductivity
  • shape memory
  • sputtering
  • electrospinning

1. Introduction

The emergence of the next-generation Fourth Industrial Revolution is, at present, promoting research on artificial intelligence (AI), the Internet of Things, information and communications technology (ICT), intelligent fibers, nanowires, and smart materials. Consequently, smart wear is becoming an item that will dominate the fiber material industry in the future. Hybrid fiber composites can have various applications, such as in healthcare, defense, fashion and entertainment, sportswear, purpose clothing, and transportation, as well as integration with advanced technology [1][2][3][4][5][6][7][8]. To date, research on cutting-edge hybrid fiber materials is being conducted [4][5][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31][32].
Materials used in smart textiles include shape-memory materials, metal fibers, conductive inks, nanoparticle optical fibers, organic semiconductors, chromic materials, and inheritance-conductive polymers. McCann introduced phase-change materials, thermochromic materials, shape-memory alloys, quantum tunneling composites for switching devices, light-emitting polymers, photovoltaics and solar cells, photoluminescence, plasma technology, microencapsulation for therapy delivery, global positioning, wireless communications, radio-frequency-identification (RFID) tags and microelectronic mechanical systems (MEMSs), and exoskeletons [33][34]. S. Lam Po Tang et al. presented smart-clothing technologies in their research. They suggested that shape-memory materials/polymers, phase-change materials, chromatic materials (thermochromic and photochromic dyes), stimuli-responsive hydrogels and membranes, and smart wearable electronics (conductive materials, flexible sensors, wireless technology, and alternative power sources) could be used as smart technology in the textile industry [35].

2. Manufacturing Techniques of Internet of Things (IoT) Hybrid Fiber Materials

2.1. Sputtering

Sputtering technology thinly coats metal onto the fiber and has an eco-friendly advantage as it does not generate wastewater. In addition, fibers that have introduced sputtering can be used as military stealth materials, smart wear using electrically conductive materials, and artificial intelligence materials [36][37][38][39]. 

Additionally, there is a study in which metal nanograins, such as aluminum, copper, and nickel, were formed on the fabric through sputtering treatment [40]. The metal layer of the magnetron sputtering fabric rapidly emits the body temperature into the open air, concealing the body in infrared thermal-imaging cameras [41]. However, the effect of stealth technology depends on the sputtering processing time; therefore, the sputtering process must be performed for an appropriate period [40][41]. In addition, a flexible and wearable electrically conductive pressure sensor was developed using SnCl4 treatment and Ag sputtering on nylon. The manufactured pressure sensor was observed to be highly reproducible and repeatable for 9500 repeated mechanical loads, with a low capacitance loss rate of 0.0534. Fabric-based flexible and comfortable sensors can be integrated into fabric garments using thermal pressure. Conductive nylon fabric in the twill structure, which showed a high conductivity rate of 0.268 Ω/cm (specific resistance), was prepared by magnetron sputtering with silver films. The flexible pressure sensor exhibited a high sensitivity value of 0.035 kPa−1 [42].

Sputtering technology is advantageous as it is environmentally friendly, has a simple manufacturing process, and produces no wastewater compared to other forms of coating technology. In addition, it has stealth technology, electrical conductivity, and electromagnetic wave blocking in which the thickness of the layer can be easily adjusted according to process changes. Therefore, as it is so versatile, it can be used as a state-of-the-art hybrid fiber in a variety of fields. 

2.2. Electrospinning

Electrospinning products can be used for protective materials, structurally colored fibers, self-cleaning materials, adsorbents, electromagnetic shielding, agriculture, low-temperature proton-exchange membrane fuel cells, solid oxide fuel cells, hydrogen storage, supercapacitors, lithium-ion battery materials, dye-sensitized solar cell applications, biosensors and biocatalysis, wastewater treatment, and air pollution control [43][44][45]. 

The thickness of the electrospun nanoweb was varied to manufacture membranes with different pore diameters. There are three main types of electrospinning devices. The first is a “high-voltage power”, which is usually 50 kV, and the second is “spinneret”, where the nozzle radiating speed is an important factor in determining fiber thickness. The third is the ink collector. The distance between the tip and collector determines the degree of elongation and the fiber thickness. Several studies have been conducted to regulate electro-radiation conditions for various variables.
Bokova et al. addressed fiber electrical rotation technology for nonwoven fabric production in various applications. In particular, they studied the conditions for forming nano- and microfibers in collagen hydrolysate and dibutyrylchitine solutions, as well as polymer complexes based on polyacrylic acid, polyvinyl alcohol, and polyethylene oxide. Comparative analyses of electrical rotations, electrical capillary tubes, and electrical nano spiders were performed. The results show promise not only for garment and shoe production, but also for the application of nonwoven fabrics in pharmaceutical hygiene practices [46].

2.3. Three-Dimensional Printing

Three-dimensional printing is a process that uses additive materials, and the starting products are manufactured by stacking the layers individually. Thus, the CAD model was physically reproduced by individually stacking materials upwards from the bottom. Cross-sectional data is required to create objects because the product is manufactured using the program.
Three-dimensional printing methods are largely solid-, liquid-, and powder-based. Solid-based models include fused deposition modeling (FDM), fused filament fabrication (FFF), and LOM (laminated-object manufacturing).
Fused deposition modeling (FDM), which is the most frequently used 3D printer, is mainly used by PLA(Poly Lactic Acid) and TPU(Thermoplastic Polyurethanes). The FDM-type filament is formed by stacking the material that is melted in the heated extruder and flows out of the nozzle onto a plate. As this method does not use a laser, it has the advantages of being a simple mechanism, having high durability and strength properties, and efficient manufacturing cost and time.
Liquid-based models include SLA (stereolithography apparatus), DLP (digital light processing), Polyjet (photo polymer jetting), and MJP (multi-jet printing).
The digital light processing (DLP) method uses a liquid photocurable resin. Liquid materials are placed in a tank where light can be transmitted, and parts are selectively cured by projecting cross-sectional images of the sculpting object onto the material, using the DLP engine. The DLP method has the advantage of producing low noise levels and sophisticated products; however, if the production size increases, the resolution decreases.
Three-dimensional printers are being used in a variety of fields at present, such as core-sheath fibers, vascular diseases, artificial organs, and intelligent textiles. In addition, previous studies have proposed a 3D-printing model that can be used for valve, vascular, and structural heart diseases [47]. 

This entry is adapted from the peer-reviewed paper 10.3390/ma16041351

References

  1. Wang, G.; Dvir, T.; Mazur, G.P.; Liu, C.-X.; van Loo, N.; Haaf, S.L.D.T.; Bordin, A.; Gazibegovic, S.; Badawy, G.; Bakkers, E.P.A.M.; et al. Singlet and triplet Cooper pair splitting in hybrid superconducting nanowires. Nature 2022, 612, 448–453.
  2. Esfahani, M.I.M.; Nussbaum, M.A. Preferred Placement and Usability of a Smart Textile System vs. inertial Measurement Units for Activity Monitoring. Sensors 2018, 18, 2501.
  3. Łaszkiewicz, B.; Kulpiński, P.; Stanisławska, A. Evaluation of diluted cellulose solutions for nanofibre production using the electrospinning method Fibres Text. East. Eur. 2017, 25, 25–30.
  4. Mikołajewska, E.; Mikołajewski, D. Integrated IT environment for people with disabilities: A new concept. Open Med. 2014, 9, 177–182.
  5. David, M. ESC Gives life to smart fabric, smart dashboard. Electron. Des. 2006, 54, 19.
  6. Kamalakannan, J.; Pavithra, T.; Tharun, R. Data Access Using IOT for Emergency Medical Services in Health Care System. Res. J. Pharm. Technol. 2017, 10, 3798.
  7. Weerasinghe, D.; Perera, S.; Dissanayake, G.K. Application of biomimicry for sustainable functionalization of textiles: Review of current status and prospectus. Text. Res. J. 2019, 89, 4282–4294.
  8. Liu, S.; Tong, J.; Yang, C.; Li, L. Smart E-textile: Resistance properties of conductive knitted fabric—Single pique. Text. Res. J. 2016, 87, 1669–1684.
  9. Rogale, S.F.; Rogale, D.; Nikolić, G. Intelligent clothing: First and second generation clothing with adaptive thermal insulation properties. Text. Res. J. 2017, 88, 2214–2233.
  10. Guo, L.; Berglin, L.; Mattila, H. Improvement of electro-mechanical properties of strain sensors made of elastic-conductive hybrid yarns. Text. Res. J. 2012, 82, 1937–1947.
  11. Romare, C.; Hass, U.; Skär, L. Healthcare professionals’ views of smart glasses in intensive care: A qualitative study Intensive Crit. Care Nurs. 2018, 45, 66–71.
  12. Grym, K.; Niela-Vilén, H.; Ekholm, E.; Hamari, L.; Azimi, I.; Rahmani, A.; Liljeberg, P.; Löyttyniemi, E.; Axelin, A. Feasibility of smart wristbands for continuous monitoring during pregnancy and one month after birth BMC Preg. Childbirth 2019, 19, 34.
  13. de Kok, M.; de Vries, H.; Pacheco, K.; van Heck, G. Failure modes of conducting yarns in electronic-textile applications. Text. Res. J. 2015, 85, 1749–1760.
  14. Locher, I.; Tröster, G. Enabling Technologies for Electrical Circuits on a Woven Monofilament Hybrid Fabric. Text. Res. J. 2008, 78, 583–594.
  15. Zhang, Z.; Song, Y.; Cui, L.; Liu, X.; Zhu, T. Emotion recognition based on customized smart bracelet with built-in accel-erometer. PeerJ 2016, 4, e2258.
  16. Wang, J.; Long, H.; Soltanian, S.; Servati, P.; Ko, F. Electro-mechanical properties of knitted wearable sensors: Part 2—Parametric study and experimental verification. Text. Res. J. 2013, 84, 200–213.
  17. Wang, J.; Long, H.; Soltanian, S.; Servati, P.; Ko, F. Electromechanical properties of knitted wearable sensors: Part 1—Theory. Text. Res. J. 2013, 84, 3–15.
  18. Kuang, Y.; Yao, L.; Luan, H.; Yu, S.; Zhang, R.; Qiu, Y. Effects of weaving structures and parameters on the radiation properties of three-dimensional fabric integrated microstrip antennas. Text. Res. J. 2017, 88, 2182–2189.
  19. Ruppert-Stroescu, M.; Balasubramanian, M. Effects of stitch classes on the electrical properties of conductive threads. Text. Res. J. 2017, 88, 2454–2463.
  20. Moradi, B.; Fernández-García, R.; Gil, I. Effect of smart textile metamaterials on electromagnetic performance for wireless body area network systems. Text. Res. J. 2018, 89, 2892–2899.
  21. Kang, X.; Liu, S.; Dai, Z.; He, Y.; Song, X.; Tan, Z. Titanium Dioxide: From Engineering to Applications. Catalysts 2019, 9, 191.
  22. Afzal, A.; Drean, J.-Y.; Harzallah, O.; Khenoussi, N.; Ahmad, S.; Akhtar, N.-A. Development of multifunctional different cross-sectional shaped coaxial composite filaments for SMART textile applications. Text. Res. J. 2016, 87, 1991–2004.
  23. Guo, L.; Berglin, L.; Wiklund, U.; Mattila, H. Design of a garment-based sensing system for breathing monitoring. Text. Res. J. 2012, 83, 499–509.
  24. Service K.P.I. Smart Textile Technology and Market Patent Analysis Report; Korea Institute of Patent Information: Seoul, Republic of Korea, 2006.
  25. Center, R.D.I. Actual Condition Analysis by High Performance High Functional Fiber Indus-try-Super/Smart/Nano/CFRP/Eco Fiber- (Knowledge Industry Information Service). Korea, 2016.
  26. Farhadi, F.; Abbasi, M.; Haghi, A.K. A stabilization of the electrospun, modified polyacrylonitril with functionalized single-walled carbon nanotubes. J. Eng. Fibers Fabr. 2021, 16, 1–13.
  27. Yuksek, M. Electromagnetic wave shielding and mechanical properties of vapor-grown carbon nano-fiber/polyvinylidene fluoride composite fibers. J. Eng. Fibers Fabr. 2020, 15, 1558925020985959.
  28. Niu, L.; Miao, X.; Jiang, G.; Wan, A.; Li, Y.; Liu, Q. Biomechanical energy harvest based on textiles used in self-powering clothing. J. Engineered Fibers Fabr. 2020, 15, 1558925020967352.
  29. Mamun, A.; Trabelsi, M.; Klöcker, M.; Storck, J.L.; Böttjer, R.; Sabantina, L. Needleless electrospun polyacrylonitrile/konjac glucomannan nanofiber mats. J. Eng. Fibers Fabr. 2020, 15, 1558925020964806.
  30. Xu, D.; Yang, W.W.; Jiang, H.M.; Fan, H.; Liu, K.S. Electromagnetic interference shielding characteristics of a core lay-er-coated fabric with excellent hand-feel characteristics. J. Eng. Fibers Fabr. 2020, 15, 1558925020959734.
  31. Spahiu, T.; Canaj, E.; Shehi, E. 3D printing for clothing production. J. Eng. Fibers Fabr. 2020, 15, 1558925020948216.
  32. Zhang, M.; Zhao, M.; Jian, M.; Wang, C.; Yu, A.; Yin, Z.; Liang, X.; Wang, H.; Xia, K.; Liang, X.; et al. Printable Smart Pattern for Multifunctional Energy-Management E-Textile. Matter 2019, 1, 168–179.
  33. Langenhove, L.V. Smart Textiles for Medicine and Health Care; CRC Press: Boca Raton, FL, USA, 2007.
  34. McCann, J.; Bryson, D. Smart Clothes and Wearable Technology; Woodhead Publishing Series in Textiles: Boca Raton, FL, USA, 2009.
  35. Tang, S.L.P.; Stylios, G.K. An overview of smart technologies for clothing design and engineering. Int. J. Cloth. Sci. Technol. 2006, 18, 108–128.
  36. Su, C.-I.; Peng, C.-C.; Lee, C.-Y. Performance of viscose rayon based activated carbon fabric modified by sputtering silver and continuous plasma treatment. Text. Res. J. 2010, 81, 730–737.
  37. Depla, D.; Segers, S.; Leroy, W.; Van Hove, T.; Van Parys, M. Smart textiles: An explorative study of the use of magnetron sputter deposition. Text. Res. J. 2011, 81, 1808–1817.
  38. He, S.; Chen, Z.; Xin, B.; Zhang, F.; Wang, X.; Liu, Y.; Peng, A.; Yang, Y. Surface functionalization of Ag/polypyrrole-coated cotton fabric by in situ polymerization and magnetron sputtering. Text. Res. J. 2019, 89, 4884–4895.
  39. Yuan, X.; Wei, Q.; Chen, D.; Xu, W. Electrical and optical properties of polyester fabric coated with Ag/TiO2 composite films by magnetron sputtering. Text. Res. J. 2015, 86, 887–894.
  40. Han, H.R.; Kim, J.J. A study on the thermal and physical properties of nylon fabric treated by metal sputtering (Al, Cu, Ni). Text. Res. J. 2017, 88, 2397–2414.
  41. Han, H.R. Characteristics of Infrared Blocking, Stealth and Color Difference of Aluminum Sputtered Fabrics. J. Korean Soc. Cloth. Text. 2019, 43, 592–604.
  42. Wu, R.; Ma, L.; Patil, A.B.; Hou, C.; Meng, Z.; Zhang, Y.; Liu, X.; Yu, W. A facile method to prepare a wearable pressure sensor based on fabric electrodes for human motion monitoring. Text. Res. J. 2019, 89, 5144–5152.
  43. Cavaliere, S. Electrospinning for Advanced Energy and Environmental Applications; CRC Press: Boca Raton, FL, USA, 2016.
  44. Ding, B.; Yu, J. Electrospun Nanofibers for Energy and Environmental Applications; Springer: Berlin/Heidelberg, Germany, 2014.
  45. Dávila, S.M.; García, C.E.P.; Perez, A.A.F. Challenges and advantages of electrospun nanofibers in agriculture: A review. Mater. Res. Express 2021, 8, 042001.
  46. Bokova, E.S.; Kovalenko, G.M.; Filatov, I.Y.; Pawlowa, M.; Stezhka, K.S. Obtaining New Biopolymer Materials by Electrospinning. Fibres Text. East. Eur. 2017, 25, 31–33.
  47. Yi, R.; Wu, C.; Liu, Y.-J.; He, Y.; Wang, C.C.L. Delta DLP 3-D Printing of Large Models. IEEE Trans. Autom. Sci. Eng. 2017, 15, 1193–1204.
More
© Text is available under the terms and conditions of the Creative Commons Attribution (CC BY) license; additional terms may apply. By using this site, you agree to the Terms and Conditions and Privacy Policy.
This entry is offline, you can click here to edit this entry!
ScholarVision Creations
Feedback