Development and characterization of stitch-basedsensors

Strain sensing seams have been developed by integrating conductive sewing threads in different types of seam designs on a fabric typical for sports clothing using sewing technology. The aim was to obtain a simply integrated stitch-based sensor that can be applied on sports clothing to monitor the movements of the upper body parts of the user during exercising. Stitch types 304; 406; 602 and 605 were produced. The seams were made on a knitted fabric composed of 80% polyamide 6.6 and 20% elastane. The seams underwent stretch cycling for 10 cycles and up to 44 cycles following EN ISO 14704-1:2005 (modified), using an INSTRON tensile tester machine. The changes in the resistance of the seams with time were recorded simultaneously using Agilent meter U1273A. Sensing functionality among which is sensor gauge factor (GF), stability, drift, and reproducibility were evaluated on the promising sensor seams. The type of base fabric used, stitch type, stitch formation process (friction and dynamic forces during sewing), integrated EC thread length, and positioning of thread(s) in the fabric have a significant influence on the performance of the seams. Sensor seam 406-001comprising 2 EC yarns (Madeira HC12) and Sensor seam 304-010 comprising 1 EC yarn (Madeira HC40) turned out to be very promising and others shall be improved (sensor 602-006 with Madeira HC 40 and sensor 605-002 with a Muriel yarn).