Direct Integration of Dynamic Emissive Displays into Knitted Fabric Structures

Smart textiles are revolutionizing the textile industry by combining technology into fabric to give clothing new abilities including communication, transformation, and energy conduction. The advent of electroluminescent fibers, which emit light in response to an applied electric field, has opened the door for fabric-integrated emissive displays in textiles. This thesis focuses on the development of a flexible and scalable emissive fabric display with individually addressable pixels disposed within a fabric matrix. The pixels are formed in areas where a fiber supporting the dielectric and phosphor layers of an electroluminescent structure contacts a conductive surface. This conductive surface can be an external conductive fiber, yarn or wire, or a translucent conductive material layer deposited at set points along the electroluminescent fibers. Different contacting methods are introduced and the different ways the EL yarns can be incorporated into the knitted fabric are discussed. EL fibers were fabricated using a single yarn coating system with a custom, adjustable 3D printed slot die coater for even distribution of material onto the supporting fiber substrates. These fibers are mechanically characterized inside of and outside of a knitted fabric matrix to determine their potential for various applications, including wearables. A 4-pixel dynamic emissive display prototype is fabricated and characterized. This is the first demonstration of an all-knit emissive display with individually controllable pixels. The prototype is composed of a grid of fibers supporting the dielectric and phosphor layers of an electroluminescent (EL) device structure, called EL fibers, and conductive fibers acting as the top electrode. This grid is integrated into a biaxial weft knit structure where the EL fibers make up the rows and conductive fibers make up the columns of the reinforcement yarns inside the supporting weft knit. The pixels exist as individual segments of electroluminescence that occur where the conductive fibers contact the EL fibers. A passive matrix addressing scheme was used to apply a voltage to each pixel individually, creating a display capable of dynamically communicating information. Optical measurements of the intensity and color of emitted light were used to quantify the performance of the display and compare it to state-of-the-art display technologies. The charge-voltage (Q-V) electrical characterization technique is used to gain information about the ACPEL fiber device operation, and mechanical tests were performed to determine the effect everyday wear and tear would have on the performance of the display. The presented textile display structure and method of producing fibers with individual sections of electroluminescence addresses the shortcomings in existing textile display technology and provides a route to directly integrated communicative textiles for applications ranging from biomedical research and monitoring to fashion. An extensive discussion of the materials and methods of production needed to scale this textile display technology and incorporate it into wearable applications is presented.Ph.D., Electrical Engineering -- Drexel University, 201

Rapid Prototyping of Slot Die Devices for Roll to Roll Production of EL Fibers

There is a growing interest in fibers supporting optoelectrical properties for textile and wearable display applications. Solution-processed electroluminescent (EL) material systems can be continuously deposited onto fiber or yarn substrates in a roll-to-roll process, making it easy to scale manufacturing. It is important to have precise control over layer deposition to achieve uniform and reliable light emission from these EL fibers. Slot-die coating offers this control and increases the rate of EL fiber production. Here, we report a highly adaptable, cost-effective 3D printing model for developing slot dies used in automatic coating systems. The resulting slot-die coating system enables rapid, reliable production of alternating current powder-based EL (ACPEL) fibers and can be adapted for many material systems. The benefits of this system over dip-coating for roll-to-roll production of EL fibers are demonstrated in this work