Functional performance of low-cost electronic yarn for E-textiles

Abstract The current work presents and discusses the design and performance qualities of braided electronic yarns for woven textiles to produce red light-intensity effects. The design process involves a simple encapsulation process with adhesive tape and a heat-shrinkable tube to secure stainless-steel conductive threads (SS-CTs) to the solder pads of light-emitting diodes. These are arranged in a series against two SS-CTs to provide single positive and negative terminals at both ends. Findings from the infrared images show that the heat distribution and dissipation of the stainless-steel conductive threads are insignificant in affecting the wear comfort of the electronic textiles on the human body. The washing test shows the robust nature of the braided electronic yarns even after 20 cycles of being subjected to high agitation and mechanical stress. A proof of concept illustrates the effectiveness of the study results, which calls on further research work to enhance the durability and flexibility of the braided electronic yarns and electronic textiles to ensure a higher level of wear comfort. These braided electronic yarns would find end applications for nighttime visibility of pedestrians, a situation that would improve the recognition of drivers for reduced collision. Graphical abstract Impact statement Electronic textiles otherwise known as e-textiles have been the subject of scholarly attention in recent years due to their performance properties and wide areas of application for entertainment, monitoring, and safety purposes. The use of appropriate electronic yarns (e-yarns) plays a key role in connectivity and provides the necessary feedback when applied to a textile material. E-yarns are now replacing a few modern electronic textiles (e-textiles) that use rigid copper wires commonly applied in electronic circuits for e-textiles and improve the wear comfort of the garment. The integration of light-emitting diodes (LEDs) into conductive threads to form electronic yarns for textile material can be applied not only for entertainment purposes but also as a safety feature for pedestrians. The use of appropriate components is necessary to ensure and maintain the textile quality and properties for effective wearability. Herein, an e-yarn fabricated with stainless-steel conductive threads and LEDs for e-textiles is presented. As part of ongoing research work to develop smart interactive clothing to increase the nighttime visibility of pedestrians, this work discusses the design and performance qualities of braided e-yarns for woven textiles. The success of these low-cost, flexible, and strong (high wash durability) braided e-yarns facilitates their integration into woven fabrics for smart clothing to enhance the visibility and therefore safety of pedestrians.