Structural influence of knitting patterns on mechanical, electrical and durability characteristics of conductive fabrics

This study investigates the influence of knitting structure on the electrical performance and durability of conductive fabrics for smart clothing applications. Fabrics with plain (PN), cable (CB), and miss (MS) stitches were knitted using cotton and silver-coated yarns, and subjected to ten cycles of artificial perspiration immersion and washing (PW). Despite using the least amount of conductive yarn, the MS structure exhibited the lowest surface resistance (3.18 Ω/m²) and the highest heating temperature (156 °C), due to its floating segments. In contrast, the CB structure showed the highest resistance (3.85 Ω /m²) and the lowest heating performance (129 °C), while the PN structure demonstrated intermediate performance (3.38 Ω /m², 148 °C) with the most stable pre-treatment resistance. These results suggest that knitting structure affects performance more than conductive yarn quantity. After 10 PW cycles, all fabrics exhibited silver oxidation, delamination, and cotton fibrillation. Resistance increased (PN: 6.72 Ω/m²; CB: 10.79 Ω/m²; MS: 4.72 Ω/m²), yet the MS structure retained the highest heating temperature (97 °C), indicating excellent electrothermal durability. However, MS showed significant dimensional shrinkage (-64%), highlighting a trade-off between performance and structural stability. Optimizing knitting structure is essential for enhancing the functionality, durability, and practicality of conductive fabrics in smart clothing applications.