Yarn‐to‐Yarn Surface Area and Roughness as Structural Engineering Tools for Optimizing the Electrical Output of Triboelectric Nanogenerators: Geometrical and Experimental Verification

Abstract This paper investigates the performance of woven triboelectric nanogenerators (W‐TENGs) fabricated with different fabric patterns, specifically plain, twill, and hopsack weaves, using wool and polyester yarns. It is intended to enhance the electrical output and efficiency of W‐TENGs for potential applications in wearable electronics by optimizing the weaving pattern. Results indicate that W‐TENGs with twill 2/2 and hopsack 2/2 patterns exhibit superior electrical outputs, attributed to their higher contact surface area and roughness. The twill 2/2 pattern demonstrates the highest electrical output, generating an open‐circuit voltage of 4.7 V, a short‐circuit current of 4 µA, and a transferred charge of 0.35 µC. This study also highlights the critical role of surface area and dielectric material roughness in determining the output performance of triboelectric structures. A theoretical model is developed to calculate the real contact surface area of the woven fabrics with different patterns. Statistical analysis reveals significant relationships between surface roughness parameters and electrical performance. Dynamic testing under varying contact forces and frequencies demonstrates the practical applicability and robustness of the W‐TENGs. Furthermore, the devices exhibit excellent durability, maintaining stable performance over extended periods. This research provides new insights into fabric design strategies for optimizing energy harvesting in wearable devices.