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Sungmee Park TEXTILES AS A META-WEARABLE: STUDIES ON TEXTILES AS AN INFORMATION INFRASTRUCTURE A Dissertation Presented to The Academic Faculty By Sungmee Park In Partial Fulfillment Of the Requirements for the Degree Doctor of Philosophy in the School of Materials Science and Engineering Georgia Institute of Technology August, 2019 Copyright © Sungmee Park 2019 TEXTILES AS A META-WEARABLE: STUDIES ON TEXTILES AS AN INFORMATION INFRASTRUCTURE Approved by: Dr. Sundaresan Jayaraman, Advisor Dr. Naresh Thadhani School of Materials Science and School of Materials Science and Engineering Engineering Georgia Institute of Technology Georgia Institute of Technology Dr. Preet Singh Dr. Donggang Yao School of Materials Science and School of Materials Science and Engineering Engineering Georgia Institute of Technology Georgia Institute of Technology Dr. Suresh Sitaraman School of Mechanical Engineering Georgia Institute of Technology Date Approved: June 5, 2019 With profound gratitude, I dedicate this thesis to My beloved Parents & My loving sister – Sunghee who have given me endless love and support throughout this journey. And to My mentor – Professor Sundaresan Jayaraman for his inspiration, encouragement, and guidance. iii ACKNOWLEDGEMENTS I gratefully acknowledge the support and guidance of my advisor, Professor Sundaresan Jayaraman. This dissertation would never have taken shape without his unending inspiration, advice, and encouragement. It has been an honor and a joy for me to perform this groundbreaking research with him. I would also like to thank the members of my dissertation committee – Professor Preet Singh, Professor Suresh Sitaraman, Professor Naresh Thadhani, and Professor Donggang Yao – for their support, encouragement, and constructive input during the course of the dissertation. I would like to extend a special thanks to Professor Naresh Thadhani (MSE School Chair), Professor Preet Singh (MSE Associate School Chair) and Ms. Dracy Blackwell (MSE Graduate Office) for facilitating the completion of my dissertation that began over two decades ago. I would also like to acknowledge support from the various funding sources for my research including the US Department of the Navy, DARPA, Georgia Tech – Emory Seed Grant Program, Kolon Industries (for the Term Professorship to Professor Jayaraman), the Imlay Innovation Fund, and the Craig H. Neilsen Foundation. Finally, I extend my deepest thanks to my parents – especially my Mom – for waiting for almost two decades for me to finish my dissertation. My PhD has been number one on her “bucket” list. I am thrilled that she can now cross it off her list! iv TABLE OF CONTENTS ACKNOWLEDGEMENTS --------------------------------------------------------------------- iv LIST OF TABLES ------------------------------------------------------------------------------- vii LIST OF FIGURES ------------------------------------------------------------------------------ ix SUMMARY --------------------------------------------------------------------------------------- xix CHAPTER 1. INTRODUCTION -------------------------------------------------------------- 1 1.1 Harnessing the Synergistic Relationship ------------------------------------------- 2 1.1.1 The Principal Dimensions of Textiles (Clothing) --------------------------- 2 1.1.2 Clothing as a Universal Interface ---------------------------------------------- 4 1.1.3 Meeting the User’s Demands: Need for Convergence ---------------------- 4 1.1.4 Enhancing the Quality of Life: Need for Convergence --------------------- 5 1.1.5 Textiles: The Convergence Platform and the Third Dimension of Intelligence ----------------------------------------------------------------------- 6 1.1.6 Innovation: The Lifeblood of the Textile/Apparel Complex -------------- 8 1.2 Motivation for the Research --------------------------------------------------------- 8 1.3 Research Objectives ------------------------------------------------------------------ 10 1.3.1 The Research Framework ----------------------------------------------------- 10 1.4 Concurrent Developments in the Field --------------------------------------------- 11 1.4.1 Smart Textiles through Printed Electronics --------------------------------- 13 1.4.2 The Smart Textiles Market ---------------------------------------------------- 15 1.5 The Organization of the Dissertation ----------------------------------------------- 17 v CHAPTER 2. TEXTILE-BASED INFORMATION INFRASTRUCTURE: DESIGN AND DEVELOPMENT METHODOLOGY-------------------------------- 18 2.1 Engineering Design of Textile Structures ------------------------------------------ 18 2.2 Quality Function Deployment ------------------------------------------------------- 20 2.3 Design Conceptualization: Detailed Analysis of the Key Performance Requirements -------------------------------------------------------------------------- 22 2.4 The Sensate Liner Design and Development Framework ----------------------- 26 2.4.1 Sensate Liner Design: Desired Set of Properties ---------------------------- 28 2.4.2 Sensate Liner: The Proposed Design and Structure ------------------------- 28 2.4.3 Realizing the Sensate Liner Design: Materials and Fabrication Technologies --------------------------------------------------------------------- 29 2.4.4 Material Evaluation and Selection --------------------------------------------- 30 2.4.5 Evaluation of Fabrication Technologies -------------------------------------- 38 2.4.6 The Design and Structure of Sensate Liner ---------------------------------- 40 2.5 Research Outcome -------------------------------------------------------------------- 40 CHAPTER 3. DEVELOPMENT OF AN INNOVATIVE MANUFACTURING TECHNOLOGY ---------------------------------------------------------------- 42 3.1 Meeting the Challenge: Need for Full-Fashioned Weaving --------------------- 42 3.1.1 Concept of a Full-Fashioned Woven Garment ------------------------------- 43 3.1.2 Transforming the Concept to Reality ----------------------------------------- 46 3.1.3 Sample Production Using the Novel Full-Fashioned Weaving Process -- 50 3.2 Novel Concept of a Full-Fashioned Garment with Sleeves ---------------------- 53 3.3 Meeting the Challenge: Preserving the Integrity of POF in the Sensate Liner -- 57 3.3.1 Penetration Sensing Capability: Impact of Signal Attenuation ------------ 60 vi 3.3.2 Effect of Bending Radius on Attenuation ----------------------------------- 61 3.3.3 SEM Studies --------------------------------------------------------------------- 62 3.3.4 Investigation of the Mechanical Properties of POF ------------------------ 64 3.3.5 Process Improvements to Minimize Damage to POF ---------------------- 66 3.4 Design Enhancements and The Second Generation Woven β-Prototype ----- 68 3.5 Research Outcomes ------------------------------------------------------------------- 72 CHAPTER 4. INFORMATION ROUTING THROUGH TEXTILES: CONCEPT OF INTERCONNECTIONS IN TEXTILE STRUCTURES AND DEVELOPMENT OF INTERCONNECTION TECHNOLOGY ------- 73 4.1 The Need: Information Routing through a Textile Structure ------------------- 73 4.1.1 Concept of Interconnection in a Textile Structure -------------------------- 74 4.2 Development of Interconnection Technology ------------------------------------- 77 4.2.1 Softening and Removal of Insulation ----------------------------------------- 78 4.2.2 Abrasion of Insulation ---------------------------------------------------------- 78 4.2.3 Application of Conductive Paste ---------------------------------------------- 79 4.2.4 Insulation of the Interconnection Zone --------------------------------------- 83 4.3 Optimization of the Interconnection Process -------------------------------------- 83 4.4 Textillography: A Novel Technology for Interconnection Architecture in Fabrics ---------------------------------------------------------------------------------- 85 4.4.1 The Conceptual Framework for Off-the-Loom Textillography ----------- 86 4.4.2 The Conceptual Framework for On-Loom Real-Time Textillography --- 89 4.5 Research Outcomes ------------------------------------------------------------------- 91 CHAPTER 5. INVESTIGATION ON MATERIALS FOR THE INFORMATION INFRASTRUCTURE COMPONENT -------------------------------------- 92 vii 5.1 Guiding Principles for Material Selection ----------------------------------------- 92 5.2 Testing and Evaluation of Conductive Yarns ------------------------------------- 94 5.2.1 Test Methods -------------------------------------------------------------------- 97 5.2.2. Testing Set-up for Electrical Properties -------------------------------------- 97 5.2.3 Results and Discussion --------------------------------------------------------- 100 5.3 Testing and Evaluation of Fabrics with Woven-in Conductive Fibers -------- 102 5.3.1 Test Methods -------------------------------------------------------------------- 103 5.3.2 Specifications of Fabric Test Samples --------------------------------------- 103 5.3.3 Test Set-up for Electrical Properties ------------------------------------------ 103 5.3.4 Results and Discussion --------------------------------------------------------- 104 5.4 Research Outcome -------------------------------------------------------------------- 106 CHAPTER 6. REALIZATION OF THE WEARABLE MOTHERBOARD ----------- 107 6.1 Design and Fabrication of the Third Generation Woven Sensate Liner ------ 108 6.1.1 The Plug and Play Modular Design: The Concept of T-Connector ------ 109 6.1.2 The integrated Woven Sensate Liner ----------------------------------------- 112 6.2 Testing and
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