Characterisation of Electrical and Stiffness Properties of Conductive Textile Coatings with Metal Flake-Shaped Fillers

Two conductive formulations containing different types of micron-sized metal flakes (silver-coated copper (Cu) and pure silver (Ag)) were characterised and used to form highly electrically conductive coatings (conductors) on plain and base-coated woven fabrics, the latter in an encapsulated construction. With e-textiles as the intended application, the fabric stiffness, in terms of flexural stiffness and sheet resistance (R_sh), after durability testing (laundering and abrasion) was investigated and related to user friendliness and long-term performance. Bare and encapsulated conductors with increasing amounts of deposited solids were fabricated by adjusting the knife coating parameters, such as the coating gap height (5, 20, 50, and 200 μm), which reduced the R_sh, as determined by four-point probe (4PP) measurements; however, this improvement was at the expense of increased flexural stiffness of the coated fabrics. The addition of a melamine derivative (MF) as a cross-linker to the Cu formulation and the encapsulation of both conductor types gave the best trade-off between durability and R_sh, as confirmed by 4PP measurements. However, the infrared camera images revealed the formation of hotspots within the bare conductor matrix, although low resistances (determined by 4PP) and no microstructural defects (determined by SEM) were detected. These results stress the importance of thorough investigation to assure the design of reliable conductors applied on textiles requiring this type of maintenance.