Continuous Forming of Weaving Guides Using a Reel-to-reel Thermal Roller Imprint

Abstract

In the emerging fields related to healthcare, energy, and environment, realization of devices on large area flexible sheets is imminent. Weaving e-textile with fibrous devices comprising warp and weft is one of the methods to realize such devices. Especially with a display or with a 2-D matrix sensor, a distortion of image, or error in positional information can occur if these matrices get misaligned. Therefore securing of the matrix becomes necessary. However, in a traditional textile, due to weak binding force in shear direction at the intersection of warp and weft, the displacement of intersection often does take place. So we propose to make a weaving guide in a form of dent structure on the fiber substrate. To realize this strategy, we developed a system to produce such weaving guides onto a fiber with improved productivity. To maintain a constant press force onto the fiber substrate during imprint, and to stabilize deformation volume, we adopted a press force control mechanism. As a result we obtained a stable and uniform deformation of imprinted weaving guides. Finally, to validate the weaving guide, we made two samples using 3×3 fibers, with and without the weaving guides. We saw distinct difference between the two samples.