Highly Conductive Hybrid Threads for E-textile Applications

Electrically conductive threads are increasingly integrated into textiles, which merge textile and electronic functionalities, thereby creating electronic textiles (e-textiles). Defined by IPC as textile structures permanently incorporating electrical functions, e-textiles have vast applications across healthcare, emergency response, sports, and entertainment. However, ensuring reliability, particularly in electrical connectivity, remains a significant challenge. This paper focuses on hybrid threads, which combine textile fibers with metallic microwires, offering enhanced mechanical durability and electrical conductivity compared to traditional metal-plated threads. In addition, electrically insulated threads can be created relatively easily without significantly modifying their optical diameter or mechanical properties. Testing hybrid threads for resistance to mechanical stress, washing, abrasion, and current load capacity is essential for verifying their performance in real-world applications. The study details the materials and methods employed in testing various hybrid conductive threads and discusses the results, highlighting the optimal current load, contact methods, abrasion resistance, and washing cycle effects on electrical resistance. These findings contribute crucial data for developing reliable e-textile applications, ensuring long-term functionality and user satisfaction.