PEDOT:PSS-Modified Cotton Conductive Thread for Mass Manufacturing of Textile-Based Electrical Wearable Sensors by Computerized Embroidery

Abstract

The textile industry has advanced processes that allow computerized manufacturing of garments at large volumes with precise visual patterns. The industry, however, is not able to mass fabricate clothes with seamlessly integrated wearable sensors, using its precise methods of fabrication (such as computerized embroidery). This is due to the lack of conductive threads compatible with standard manufacturing methods used in industry. In this work, we report a low-cost poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS)-modified cotton conductive thread (PECOTEX) that is compatible with computerized embroidery. The PECOTEX was produced using a crosslinking reaction between PEDOT:PSS and cotton thread using divinyl sulfone as the crosslinker. We extensively characterized and optimized our formulations to create a mechanically robust conductive thread that can be produced in large quantities in a roll-to-roll fashion. Using PECOTEX and a domestic computerized embroidery machine, we produced a series of wearable electrical sensors including a facemask for monitoring breathing, a t-shirt for monitoring heart activity and textile-based gas sensors for monitoring ammonia as technology demonstrators. PECOTEX has the potential to enable mass manufacturing of new classes of low-cost wearable sensors integrated into everyday clothes.

Bioinspired Stretchable Transducer for Wearable Continuous Monitoring of Respiratory Patterns in Humans and Animals

“…[41][42][43][44][45][46] Notable works include strain sensors based on textiles, conductive polymer composites, or microfabricated adhesive patches with metal electrodes. [47][48][49] These sensors require either complex manufacturing technologies or rely on custom formulations of materials that cannot be purchased off the shelf. These two critical issues lead to poor reliability and increased costs, eventually slowing clinical translation and reducing the applicability of the devices produced in real-world settings.…”

Bioinspired Stretchable Transducer for Wearable Continuous Monitoring of Respiratory Patterns in Humans and Animals

“…40–45 Notable works include strain sensors based on textiles, conductive polymer composites, or microfabricated adhesive patches with metal electrodes. 46–48 These sensors require either complex manufacturing technologies or rely on custom formulations of materials that cannot be purchased off the shelf. These two critical issues lead to poor reliability and increased costs, eventually slowing clinical translation and reducing the applicability of the devices produced in real-world settings.…”