Polyvinyl butyral is used in safety glass interlayers, mainly in car windshields. Legislative regulations require a recycling of cars after their lifetime and therefore also their safety glass. This causes the availability of recycled polyvinyl butyrate (r-PVB) originated from safety glass interlayers. Due to deteriorated optical properties, such as the transparency, and unknown amounts of plasticizers, it is challenging to reuse the recycled material in new windshields. Therefore, it is of particular interest to find new fields of application for r-PVB, such as the usage as a textile coating. In this research, r-PVB was investigated as a material for yarn coating. Polyester and polyamide mono- and multifilament yarns were coated continuously with solely a polymer dispersion and with mixtures of crosslinking agent and polymer dispersion. Crosslinked r-PVB coatings showed enhanced properties toward abrasion and chemical resistance. Coatings without the crosslinking agent showed a diminished abrasion resistance and could be washed off with ethanol. Mechanical properties of the monofilaments were influenced by the r-PVB coating in general. However, varying concentrations of the crosslinking agent did not affect the mechanical properties.

Monitoring of humidity is a widespread application for process control, lifetime assessment of components and assemblies, environmental control systems, medical textiles, working clothes and personal safety systems. To allow spatially resolved mapping of this parameter over a larger textile surface, discrete sensor elements are presently placed separately onto the textile material. Hence, the actual integration level of sensors in textile materials and therefore the value creation is rather low. To achieve a higher integration level textile sensors are needed. To serve this need the development and characterization of different textile-based humidity sensors using spinning, printing and coating technologies is described in this paper. It was shown that the developed sensors were sensitive towards relative humidity in the range of 25 to 80 % rel. humidity.

Electrochromic devices can act as passive displays. They change their color when a low voltage is applied. Flexible and bendable hybrid textile-film electrochromic devices with poly-3,4-ethylenedioxythiophene polystyrene sulfonate (PEDOT:PSS) were prepared on polyethylene polyethylene terephthalate (PEPES) membranes using a spray coating technique. The electrolyte consisted of a gelatin glycerol mixture as host matrix and calcium chloride. Titanium dioxide was used as an ion storage layer and a carbon containing dispersion was used for the counter electrode on a polyester rip-stop fabric. The sheet resistance of PEDOT:PSS on PEPES was 500 Ohm/sq. A 5 × 5 electrochromic matrix with individually addressable pixels was successfully designed and assembled. The switching time of the pixels was 2 s at a voltage of 2.0 V directly after assembling. The use of titanium dioxide as ion storage also increased the contrast of the dark-blue reduced electrochromic layer. Coloration was not self-sustaining. The PEDOT:PSS layer needed a constant low voltage of at least 0.5 V to sustain in the dark-blue reduced state. The switching time increased with time. After 12 months the switching time was ~4 s at a voltage of 2.8 V. The addition of glycerol into the electrolyte extended the lifetime of a non-encapsulated textile electrochromic cell, because moisture is retained in the electrolyte. Charge carriers can be transported into and out of the electrochromic layer.

Embroidery is often the preferred technology when rigid circuit boards need to be connected to sensors and electrodes by data transmission lines and integrated into textiles. Moreover, conventional circuit boards, like Lilypad Arduino, commonly lack softness and flexibility. One approach to overcome this drawback can be flexible sequins as a substrate carrier for circuit boards. In this paper, such an approach of the development of flexible and functional sequins and circuit boards for wearable textile applications using subtractive and additive technology is demonstrated. Applying these techniques, one-sided sequins and circuit boards are produced using wax printing and etching copper-clad foils, as well as using dual 3D printing of conventional isolating and electrically conductive materials. The resulting flexible and functional sequins are equipped with surface mounted devices, applied to textiles by an automated embroidery process and contacted with a conductive embroidery thread.

The need for more efficient health services and the trend of a healthy lifestyle pushes the development of smart textiles. Since textiles have always been an object of everyday life, smart textiles promise an extensive user acceptance. Thereby, the manufacture of electrical components based on textile materials is of great interest for applications as biosensors. Organic electrochemical transistors (OECTs) are often used as biosensors for the detection of saline content, adrenaline, glucose, etc., in diverse body fluids. Textile-based OECTs are mostly prepared by combining a liquid electrolyte solution with two separate electro-active yarns that must be precisely arranged in a textile structure. Herein, on the other hand, a biosensor based on a textile single-component organic electrochemical transistor with a hardened electrolyte was developed by common textile technologies such as impregnation and laminating. Its working principle was demonstrated by showing that the herein-produced transistor functions similarly to a switch or an amplifier and that it is able to detect ionic analytes of a saline solution. These findings support the idea of using this new device layout of textile-based OECTs as biosensors in near-body applications, though future work must be carried out to ensure reproducibility and selectivity, and to achieve an increased level of textile integration.

A person’s body temperature is an important indicator of their health status. A deviation of that temperature by just 2 °C already has or can lead to serious consequences, such as fever or hypothermia. Hence, the development of a temperature-sensing and heatable yarn is an important step toward enabling and improving the monitoring and regulation of a person’s body temperature. This technology offers benefits to several industries, such as health care and sports. This paper focuses on the characterization and development of a hybrid yarn, which can measure and visualize temperature changes through a thermoresistive and thermochromic effect. Moreover, the yarn is able to serve as a flexible heating element by connecting to a power source. The structure of the yarn is designed in three layers. Each layer and component ensures the functionality and flexibility of the yarn and additional compatibility with further processing steps. A flexible stainless steel core was used as the heat-sensitive and heat-conducting material. The layer of polyester wrapped around the stainless steel yarn improves the wearing comfort and serves as substrate material for the thermochromic coating. The resulting hybrid yarn has a reproducible sensory function and changes its resistance by 0.15 Ω between 20 and 60 °C for a length of 30 cm. In addition, the yarn has a uniform and reproducible heating power, so that temperature steps can be achieved at a defined length by selecting certain voltages. The thermochromic color change is clearly visible between 28 and 29 °C. Due to its textile structure, the hybrid sensory and actuating yarn can easily be incorporated into a woven fabric or into a textile by means of joining technology sewing.