International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882
Volume 3 Issue 2, May 2014
THE DEVELOPMENT OF THE WINTER JOGGING CAP
Engr. Muhammad Qamar Khan (Lecture National Textile University Karachi),
Muhammad Faizan, Sajida Hafeez, M. Sabeehul Hassan, Wazeer Husain, Muhammad Umer
Abstract
This research project represents an E-textile, a
wearable music system, which is a winter jogging cap.
This cap is designed to entertain the music lovers
during jogging in winters. Cap is equipped with MP3
circuit, rechargeable battery (3.7V) and headphones.
All circuits are embedded in knitted cap by conductive
thread. This cap provides comfort to user during
jogging. This project explains how all these electronic
components can be embedded in a cap making it easily
wearable
are compatible with each other. This generation has
opened the new path towards true electronic textiles. In
this generation wearable electronics blend into textile
materials. Electronic components are integrated in
textile yarn. Fabric having warp of silk thread and a
weft of silk thread wrapped with copper foil is an
example of this generation. It combines the functions
of both textile yarn and copper conductor. It is a hybrid
level. “SIGURD WAGNER “described that E-yarns in
which electronics are integrated at yarn level by
weaving, are used to make functional circuits.
A simple example of this is illustrated in figure 1.1.
Keywords: Conductive yarn, MP3 circuit, spun core
yarn.
1. Introduction
This section is divided into four main parts. First part
of this chapter is on E-Textiles. Second part of this
chapter is on Interactive electronic textile technologies
and third part is on Conductive threads embedded into
the garments, its uses and importance. Fourth part
consists of applications of E-Textiles. This chapter
also contains the images and E-Textile products.
1.1. E-Textiles
In the past, clothing integrated with electronic
components was only portrayed in science fiction.
Textile and apparel products containing electronic
components are no longer science fiction. Textile
based products are being developed which allow the
users to easily move with electronics components.
These textile products have potential to keep us
informed, connected and entertained. E textiles are
also called electro textiles or electronic textiles. E
textiles have evolved from the wearable computer
technology. U.S and Europe have introduced this
technology to the world. U.S Armed Forces and
Clothing companies have started to make products that
carry electronic systems. E-textiles have three different
generations from added on electronics to integrated
components with yarn.
First generation of wearable computer has system
which is wearable but it is not integrated into fabric.
These textiles are only body mounted. Second
generation of wearable computer has the system which
is wearable and the system is integrated on clothing
called surface mounted electronics. Third generation of
wearable computing systems have equal importance of
both clothing and electronic functions. Their functions
Figure 1.1 Series connection of solar cells by weaving
In figure 1.1 Black segments are solar cells and grey
segments are insulating areas of fibers. Two groups A
and B are shown in figure 1.1. Fiber segments are
electrically connected on both sides in group A. Fiber
segments 1A through 4A are connected in series in
numerical order. Therefore fibers and voltage add must
be arranged such that each fiber segment has the same
photocurrent. Group A is connected with group B by
connecting the top contact of 4A to bottom contact of
4B in series, asshown in figure 1.1. [1]
1.2. Conductive yarns
Just two materials can be used for the production of
conductive yarns; these materials include conductive
and optical fibers. Electrically conductive textiles can
be produced by using conductive yarns. Conductive
yarns are produced by the wrapping of silver, copper
or gold foil on to non-conductive yarn/ filament to
provide conductive properties. It is believed that the
use of metallic yarns in decorative fabrics was
originated in India and is being used since mid-18th
century. One example in this field of technology is
metallic silk organza. This is a woven silk fabric.
Metallic silk organza is produced from two types of
yarns which include silk yarn as warp and silk as weft
wrapped in thin capper foil or thread as shown in
figure 1.6. This thread is produced just like a clothcore telephone wire and is highly conductive (~0.1
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882
Volume 3 Issue 2, May 2014
Ω/cm) i.e. very low resistance. In highly conductive
yarns silk core is used. Silk yarn is transformed into
this conductive yarn by copper threads. The tolerance
for high temperature and high tensile strength are
improved due to the physical properties of silk core
allowing it to be embroided or sewn on industrial
machinery without any damage to the machinery. Due
to these properties the metallic yarns are very capable
for mass production of interactive electronic textiles.
1.5. Garment with speaker function
Dar-Ming Chaiang& Jen-Yuh Jiang” invented garment
with a speaker function in year 2009, in his article he
wrote that he used Garment body, bag and electrets
speaker. Bag is disposed on the garment body includes
a sound absorbing layer. The electrets speaker is
disposed on the garment and the sound absorbing layer
is used to absorb the sound of the specific direction
therefore enhancing the acoustic quality.[10]
1.6 Cap for retaining an audio system
In 2011, “Patrick T. Ryan” continued previous work
and made a baseball styled cap that retains an
elasticized sleeve on the inside, from wall of the cap.
A potable audio player was inserted into the sleeve and
connected to pre-installed wiring and speaker system
that is integrated into the fabric seam of the cap. He
said that this cap provide with audio system, can be
worn and used in comfort with little or no limitation on
the physical activity of the wearer. [11]
Figure 1.2 Micrograph of metallic silk organza
1.3. Musical Garment
In market there are many types of products present that
are ranging from snowboards jackets to hoodies in
which music player are integrated and can be
controlled by using buttons. Some of the elucidations
take the hardware of music player and initiate them on
the sleeve or lapped inside by the use of E-textiles.
“JuilHeo” back in 2001 also designed a garment,
capable of playing music. He used sound synthetic
chip and Sound output element. For this purpose he
made holes in the garments for the buttons, where he
used switch empowered by a battery. Moisture proof
paper positioned between an inner surface of said nonwoven fabric pocket and rear surface of the printed
circuit board. [7]
1.4. Mp3 jacket with wireless remote control
Adding more into the previous work an mp3 jacket for
carrying mp3 player with wireless remote control was
presented. “Nai Chung Tsai” used removable
electronics, so the jacket can be easily washable.
However, some like products have all parts assembled
permanently to the garment but have drawbacks.
Although the products are water proof, still they are
difficult to wash. It is also difficult to manage tracks in
the music player and you cannot change the music
player with a newer model. This garment has a first
pocket for carrying an mp3 player and the second
pocket for wireless remote control and jacket pullover
to hold earphones. [8]
Figure 1.3 Cap with music system
2. Materials
In this chapter design and materials used in smart cap
are discussed. Components used in smart cap are Mp3
player, Battery, Headphone and woven fabric. These
are integrated in a knitted cap by using conductive
thread and silicone sealant. Lock stitch machine is
used for stitching.
Knitted cap is selected for this project because it has
two layers and integrated circuit is invisible in this cap.
Winter caps are normally knitted and they completely
cover the ears. Characteristics of cap are described in
table 2.1.
Table 2.1 Characteristics of knitted cap
Wales per inch on face
9
Courses per inch on face
15
Wales per inch on back
7
Courses per inch on back
15
Machine type
Flat machine
GSM
800
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882
Volume 3 Issue 2, May 2014
Available woven fabric was used in cap to integrate
the circuit. Its properties are described in table 2.2.
Fabric is shown in figure 2.1.
provided with the music. Its characteristics are
described in table 2.4 and it is shown in figure 2.4.
Table 2.2 Characteristics of woven fabric
Weave type
3/1 Twill
GSM
219
Table 2.4 Characteristics of battery
Company
Nokia
Length
5.3 cm
Width
3.4 cm
Height
0.45 cm
Figure 2.1 Woven fabric stitched with conductive
thread
Figure 2.4 Battery
Available MP3 of smallest possible size in market was
used in Cap on the basis of comfort for wearing
purpose. Its characteristics are described in table 2.3
and it is shown in figure 2.2.
Small head phones of Sony, model MDR-Q140 were
used in cap which provided comforts as well as they
were invisible in cap. They are shown in figure 2.6.
Table 2.3 Characteristics of MP3 Player
Company
G2 Multimedia
Model
G3-07
Width
2.79 cm
Length
4.06 cm
Height
1.27 cm
Figure 2.5 Head phone
Figure 2.2 Music player (MP3)
Micro SD card of 2 Gb was used to store data as
shown in figure 2.3. 200 Mp3 songs can be stored in it.
Conductive thread was used as a sewing thread to
transfer the electric signals from MP3 player to head
phones instead of wires. So that easy handling and
comfort can be provided. It was taken as bobbin thread
and in needle staple spun PC thread was used.
Conductive thread consisted of steel wires therefore it
cannot be used as needle thread. Wear and tear effect
can damage the conductive thread. Furthermore it was
needed to be straight without making any loop. That is
why it was used in bobbin. Conductive thread used in
this project is corespun. It is made up of steel core with
10 steel wires wrapped with a cotton cover. Its
resistivity is 1.114 (Ω/m) and conductivity is 0.897
(S/m). It was measured by Ohammeter.Conductive
thread is shown in figure 2.6.
Figure 2.3 Micro SD card
Rechargeable Li-Ion battery of 3.7 volt was used. This
battery provides more operating time than the battery
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882
Volume 3 Issue 2, May 2014
Figure 2.6 Conductive thread
To laminate the conductive thread and to attach the
MP3 player, headphones with woven fabric silicone
sealant was used as shown in figure 3.4. Wires were
connected with conductive thread by soldering.
Silicone sealant is shown in figure 2.8.
Whole circuit was made according to circuit diagram
as shown in figure 3.2. In stitching first of all
conductive thread was taken as bobbin thread and in
needle staple spun PC thread was used.Tension of
bobbin thread was more than the needle thread so that
conductive thread did not pass through fabric. Then
conductive thread stitched on woven fabric of 18
inches length at 8 SPI as shown in figure 2.2. Length
of conductive thread from the center of fabric was 7
inches on both sides according to measured data.
Headphone input pin was attached at one end of
conductive thread by soldering similarly headphones
were attached at the other end. Circuit of MP3 with LiIon battery (3.7V) was made then this MP3 circuit was
attached with Head phone Input pin. Circuit adjusted
in such a way that its charging port was laid at the
bottom of cap. So that battery can be charged. Whole
conductive thread was laminated with silicone sealant
to avoid moisture and short-circuit. All components
were fixed on fabric with the help of silicone sealant.
Then this whole circuit was covered by stitching a
woven fabric on it. A piece of fabric was cut from the
face of headphones to avoid hindrance in voice quality.
Complete circuit is shown in figure 3.4.
Figure 2.7 Silicone sealant
Single needle lock stitch machine JUKI DDL 5550
was used for stitching. JUKI was chosen on the basis
of their superior quality of sewing machines. Machine
is shown in figure 2.8.
Figure 3.2 Circuit diagram
Figure 2.8 Lock stitch machine
3. Design
3.1.2 Construction of Circuit
Conductive thread was stitched using single needle
lock stitch machine (Class 301).
Figure 3.1 Stitch types 301
Figure 3.3 Complete circuit
3.1.3 Testing
After completion circuit was checked for a day and it
was fine. Signal transmission was proper.
3.1.4 Circuit Integration and position
After testing, this woven fabric with all electronic
components was stitched by hand stitching between
the two layers of cap on back side according to the
measured data. This MP3 circuit was stitched at center
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International Journal of Scientific Research Engineering & Technology (IJSRET), ISSN 2278 – 0882
Volume 3 Issue 2, May 2014
on back side of cap in such a way that SD card can be
removed from cap. One end of charging cable was
fixed with MP3 and the other end free outside of cap.
Then only portion of headphones was stitched at 7
inches from MP3 circuit on both sides in cap by hand
stitching. Folded the layers of cap and stitched them at
top of cap. In this way our product was ready for use.
References
[1] S. Wagner, “Electrotextiles: Concepts and
challenges,” International journal of high speed
electronics and systems, vol.12, no.2, pp. 391339,2002.
[2] Martin and Thomas et al, "Towards a design
framework for wearable electronic textiles." ISWC,
vol.3, 2003.
[3] S. Mann, “A First Step toward Personal
Imaging,”Wearable Computing, vol. 30, no. 2,
February 1997.
Figure 3.4 Smart cap
4.1 Conclusion and Limitations
Such innovative smart cap should be manufactured to
maximize the chance of sustainability of the textile
sector in Pakistan as it’s a highly value added product.
Smart cap is developed for entertainment. Volume of
music in cap was maintained in such a way that the
people in surrounding wound not be disturbed. The
prime use of this cap is to use it for weather protection
and for listening music during jogging. This is a better
choice than other available options i.e. mobile phone
and music player. The music player and mobile phones
are not user friendly as they have got the wires i.e.
Hands free which could compromise the comfort of
the user.
[4] D. Meoli, "Electronic textiles: Technologies,
Applications, Opportunities, andMarket potential,"MS
thesis, North Carolina State University, Raleigh, May
2002.
[5] T.Mayplumlee and D. Meoli, A review of
Technologies,
Interactive
electronic
textile
Development, vol.2, no.2, Spring 2002.
[6]Buechley L, "A Construction Kit for Electronic
Textiles," Wearable Computers, vol. 83, 90, pp. 11-14,
Oct. 2006.
[7] J.H. Seoul (KR), “Garment capable of outputting a
sound”, U.S. Patent 6192137, Feb 20, 2001
4.1.1 Operating Procedure
Wear the smart cap in such a way that Mp3 player
remains on back side of head. Buttons are on back side
of cap, labeled by +, –, <,> and P. Buttons “+,-” are
used to control the volume and “<, >” are used to
move on next or previous track. When you want to
listen music press the button P, similarly when you
want to pause it press the same button P. Similarly to
move on next or previous track and to increase or
decrease the volume, follow the same procedure on
buttons. To exchange the data plug USB connector
into computer.
4.1.2 Limitations
1. Battery should be recharge after 20 hours for one
hour.
2. Avoid
washing,
only
dry-cleaning
is
recommended.
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