Coating of yarn with PEDOT-PSS : An examination of optimal manufacturing parameters in a dip coating production line for conductive yarn.

Electrically conductive smart textiles are a very interesting area that could be important for the development of smart textiles. Today, conductive yarns and threads are often produced from coveted metals such as silver, copper and gold. These metals require large resources to be extracted and processed into yarns and threads and have a major impact on humans and the environment. One way to reduce the consumption of metals and save resources is to coat yarns of textile materials with electrically conductive polymers. In this study, we will investigate coating yarns with the conductive polymer blend PEDOT-PSS. PEDOT-PSS is extracted from oil, which is a non-renewable raw material, but coating with this polymer dispersion has many other advantages over metals and its production chain. Like coating yarn through a chemical bath produces very little waste, the yarn has a smaller mass, the yarn becomes more flexible, and it is easy to scale up production. However, previous studies have shown that there are some difficulties when it comes to coating yarns with PEDOT-PSS. The coating becomes fragile and brittle and to some extent affects the yarn that is coated in terms of mechanical properties. In this study, its investigated how the yarn is affected by various parameters in the production line, such as drying temperature, the viscosity of the PEDOT-PSS dispersion and the speed of the thread traveling through the production line, to find optimal production parameters that provide a balance between conductive and mechanical properties. We have produced a number of samples, all with different variations of parameters, and investigated how its conductive and mechanical properties are affected to see if there is a pattern and connection between parameters and conductive and mechanical properties on the yarn. The results show that yarn samples made with high viscosity of the PEDOT-PSS dispersion are among the lower range of resistance (with some exceptions), with average values of about 2990 O up to 10300 O, while lower viscosity shows uneven results with average values of about 92,000 O and all the way up to about 6,500,000 O. Most samples with lower measured O values are made with a high drying temperature, but no clear connection could be detected between temperature and end result, nor did the different speeds show any clear connection to the result. For the mechanical properties, it turns out that there is a relationship between result and viscosity as well as result and drying temperature. Samples made with low viscosity and low drying temperature perform best in the mechanical tests, 59.7% to 52.9% elongation and 25 cN / tex to 21 cN / tex. While speeds in this category could not show any connection between the results either. Overall, the results can be summarized as the results of tests show that there are some correlations between the parameters and the properties of the yarn samples and that the viscosity of the PEDOT-PSS dispersion and drying temperature are the most influential parameters. For conductive properties, viscosity has the greatest effect and for mechanical properties, viscosity and temperature have the greatest effect. For conductive properties, high viscosity is good, and for mechanical properties, low temperature and low viscosity are best. The sample with the best combination of test results was tested in a knitting machine but the variant chosen for knitting did not have good enough mechanical properties for the knitting machine used and broke when exposed to the stress from the knitting process. Therefore, the knitting test was not successful, but it was possible to sift out what parameter of the production line that had the greatest impact on the coated yarn properties.