the institute for special textiles and flexible materials · the global smart textile market was...

The Institute for Special Textiles

and Flexible Materials

Automated Manufacturing of Textiles

with Integrated Electronic

Components

Uwe Möhring, Kay Ullrich

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Textile International Forum and Exhibition 20155.-7. October 2015 Taipei, Taiwan

Outline

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• Short Introduction of TITV

• Textiles and Electronics on the Market

• Background of Interconnection

• Types of Interconnection

• Automated Mounting of Components

- Perspective of Electronics

- Perspective of Textiles

• Summary

Short Introduction of TITV

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Founded 1992 in Greiz, Germany

Team 60 experts (e.g. textile engineers, physics,

chemistry, medical engineering, electro technology)

Funded research projects approx. 25 p.a.

- BMBF (growth cores, supporting programmes)

- BMWi (IGF-AiF, Inno-Watt, Inno-Kom-Ost, ZIM)

- EU

- Federal state

Tailor-made research and development activities

on request of clients

Topics of research

- Smart textiles

- Functional surfaces

- Special textiles

Accredited testing laboratory

Technology available at the TITV Greiz

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Textile Construction

Special thread technology

Weaving including narrow fabrics

Spacer fabrics, Warp Knitting

Braiding

Surface technology

Physical / Chemical Vapour

Deposition (PVD/CVD)

Modular coating, laminating

Electroplating of textile materials

Dying / finishing

Digital printing

Technology available at the TITV Greiz

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Embroidery

Multi-head and large-scale embroidery

Special embroidery technology for the

production of circuit boards and

the assembly of components

Laser technology

Sewing technology, CAD

Electronics

Measurement and control technology

Testing technology for smart textiles

Technology for the assembly of components

on textile surfaces and threads

Bonding technology for textiles

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Accredited testing laboratory

Accredited acc. to

DIN EN ISO/IEC 17025:2005

Physical tests for textiles

Material testing

Pollutant analysis

Testing of reliability of

smart textiles

Research Focus

Outline

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• Summary

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Grupo Antolino

PHILIPS

© GERMENS; TITV Greiz FORSTER ROHNER AG

TITV Greiz

Interactiv Wear AG

Electronic Components for Luminous Textiles

Adam Opel AG

IAC Group GmbH

Nike

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Porsche

AG

warmX GmbH

Electronic Componentes for Textile Heating

Alpenheat

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BMW

TITV Greiz Hexoskin Wearable Body Metrics

Electronic componentes for Textile - Human -

Interaction

Touch Glove Ally SeeleySwany

Studio (n-1) Architects

http://winfwiki.wi-fom.de/images/e/ee/Lifekeeper.jpg

http://winfwiki.wi-fom.de/images/e/ee/Lifekeeper.jpg

Electronic Components in Textiles for Pain

Therapy

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PHILIPS

TITV Greiz

PHILIPS

Bomedus GmbH

The global smart textile market was estimated to be

USD 289.5 million in 2012 and expected to exceed

USD 1,500 million by 2020.

The main growth sector in the last 3 years has been

in the protection and military clothing sector

and it is estimated to remain the largest market segment in the next six years.

Sport and fitness applications are predicted to see the fastest growth along

with health and medical applications.

References:

http://www.grandviewresearch.com/industry-analysis/smart-textiles-industry

http://www.ohmatex.dk/pdfer/whitepaper_smart_textiles.pdf

Smart Textiles Market

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What are the barriers and opportunities in the smart textiles market ?

Outline

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• Summary

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Interconnection / Assembly of Electronic

Components

State of the art

The established connection technology is highly

tailored to conventional systems and solutions, like

cabling.

Main application

Main application at the moment is the assembly of

electronic components.

Challenge

Extension and adaptation on textile requirements.

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• Intelligent clothing (luminescent textiles, energy- and

data transmission)

• Heating textiles (heatable fabrics, medical devices)

• Electronic machinery (flexible interconnections in

household applications, security systems,

instrumentation etc.)

• Automotive (integration of heating systems and

miniaturized electronic components)

• Sports-, leisure and wellness products

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New interconnection technologies are

necessary for textile applications

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- Low Cost

- Time efficient

- Compact design

- Safe and reliable under using conditions

- Permanence of the properties

- Textile like properties (e.g. Flexibility)

- Process capability

Requirements

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• Summary

Outline

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• Crimping

• Piercing

• Winding technology

• Velcro / metallized burdock

• Snap fastener

• Embroidery

• Weaving

• Soldering / gluing in combination with textile processes

Types of Interconnection

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Types of Interconnection – Crimping

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Interconnection ELITEX-I / wire

4 mm

Interconnection ELITEX-I / ELITEX-I

Interconnection thread / wire

For compounds of thread-like structures and components with linear

expansion is the crimping technique well suited as a base technology

and ensures high reliability and effectiveness.

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Types of Interconnection – Crimping

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Interconnection thread or wire / surface

For wires, cords, conductive threads and wired components the method can

be regarded in principle.

For interconnections in areas where both contact points are already fixed (for

example stitching by Soutage-technology) there are fundamental problems.

The damage of the textile by the crimping tool can not be avoided (upper and

lower tool meet in a mechanical way).

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Types of Interconnection – Piercing

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Source: Catalogue Nicomatic

Piercing: Usually in one step a cutting tip is generated by a preform, punched

in the contact area and then closed at the bottom of the structure by an anvil.

• Used in microelectronics for embossing of connector pins, connecting

flexible printed circuit boards or other conductive foil, linking between

flexible and rigid circuit boards

• Allows the penetration of a contact in conductive (textile) areas and fits

well with textile behaviour. There are conventional technologies available

• Machines and processes still need to be adapted for textile use.

Interconnects only on one side

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Types of Interconnection – Piercing

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Textile bus-system with 4 conductive lines

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Types of Interconnection – Winding

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Preparation with

conductive varnishwinding,

Cut off remains

Secure the connection

Winding and Wire-Wrap technology was used in automation and computer

technology in the 1960s and 1980s.

• Corresponds very well to the conditions of conductive textile fibers (soft,

gentle and flexible connection)

• High manual effort if any small machinery (wrap gun) is not available and

high demands on the skill and practice of the performer

• Superseded in favor of soldering

• For the connection of conductive threads each other or threads with

metallic strands there are almost no reliable alternatives

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Metallized burdocks are newly developed and still an issue in

research. They were originally intended for the mechanical fastening

of sheet metal parts for quick assembly.

Two-piece construction similar to Velcro (hook and loop), but much

more stable than Velcro

Types of interconnection – Metallized burdock

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The hooks (about 2 mm in height)

reach into the metallic Velcro.

By pressing the two joint partners

they get hooked up there.

source: Christoph Hein

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Interconnection between conductive surfaces

Types of Interconnection – Velcro

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1 3

46

2

13

57

2

1 3

1 3

2

2

4

5

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< 0,5 W

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Types of Interconnection – Snap Fastener

Embroidery / weaving of conductive area

for attachment of snap fasteners

conductive yarn ELITEX® 235 dtex /

ELITEX® 110 dtex x 2 is used

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Therapy glove for electromyostimulation

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Type of Interconnection - Weaving

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Textile Circuits – Woven Circuits

Woven textile multilayer structure

for a RFID antenna

Integration of

circuit layout

source: www.lumalive.com

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Types of Interconnection – Embroidery

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Various layouts

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Textile Circuits – Embroidered Circuits

Sample

measuring of skin resistance by textile electrodes

measuring of skin temperature by common electronic devices


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Outline

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• Summary

Standard machines in the electrical industry

• Optical recognition

• Accuracy

• Reproducibility

• Textile has different dimensions

• Defined shapes «» flexibility

• Textile handling

• Reel to reel

Pick and Place Technique for

Electronic Components on Textiles

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• Realized ribbon handling

• Mounting on textile substrate

• Cutable

• Easy assembly into textiles

TITV‘s Pick and Place for Textile Ribbons

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Outline

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• Summary

Mounting Devices and interconnection by using

solder / conductive glue at a embroidery machine

solutions for mounting devices on textile fabrics

1. Integrating pick and place

2. Using standard embroidery technology

Pick and Place and Embroidery

To our solution

Tajima TCWM TRIPPLE-QUATTRO

From the vision

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Mounting devices on textile fabrics using 4 different heads

1. Embroidery with conductive thread material

2. Dispensing of solder

3. Pick and Place of components

4. Hot air / laser soldering

5. Functionality test

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Embroidery- head

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Dispenser-head


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Pick and Place-head


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Laser-head


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Mounting devices on textile fabrics is a combination of

electronic and textile technology.


Outline

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• Summary

Mounting components – Sequin Technology

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Functional Sequin Device Technology

Functional Sequin Device - FSD

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FSD - Functional Sequin Device Technology

Mounting devices on textile fabrics using 1 head and 1 process step

1. Fixation of sequins including the component with normal thread

2. Interconnection with conductive thread


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FSD - Functional Sequin Device Technology

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FSD- Functional Sequin Device Technology

Outline

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• Summary

Pick and Place machine with textile handling

Investment: Machine

Additional module for textile handling (prototype)

Industrial Benefits: Optical recognition is a challenge

Quantity and quality

Flexibility: Very high due to a variety of components

many textile substrates (thread, ribbon, fabric)

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Adaptation of Pick and Place in to textile machines

Pick and Place with an embroidery machine

Investment: Novel embroidery head (prototype)

Software modification

Industrial Benefits: Combination of two effective technologies

For large-scale circuit boards

Flexibility: Very high due to a variety of components

Modular expandable

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Use of components mounted to FSD`s

Conventional Embroidery Machine to

mounted electronic Components

Investment: processing head with minimal modifications

depending of the embroidery machine

Industrial Benefits: First applications deducible

Standard textile process

Flexibility: Lower (one component on FSD reel)

Quick exchangeable FSD reel

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Thank you for your attention!

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We clear the way for the

automated manufacturing

of textiles & electronics!

Textilforschungsinstitut

Thüringen – Vogtland e. V. (TITV)

Zeulenrodaer Straße 42

07973 Greiz

Phone.: +49 (0) 3661 – 611 0

Fax: +49 (0) 3661 – 611 222

[email protected]

www.titv-greiz.de

Trade Fair For All Funktional Textiles – mtex+

54

6th International Trade Fair For Technical Textiles

31. May to 02. June 2016 Chemnitz, Germany

the institute for special textiles and flexible materials · the global smart textile market was...

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