Abstract: A flexible electrode device, including a typically thin film polymer layer, a typically thin film metal layer bonded to the polymer layer to yield a composite strip, and a polymer substrate ultrasonically welded to the composite strip to yield a flexible electrode device. The flexible electrode device exhibits electrical conductivity of at least 1.08×106 S·m?1, at least 60% tensile elongation, and less than 5% change in the R/R0 after 50 peeling cycles. The flexible electrode is formed without annealing and is formed under ambient pressure and temperature conditions. The flexible electrode device can have any convenient shape.

Abstract: Electronic textiles and systems and processes associated therewith. A dual regime spray system allows the formation of electrically conductive polymers in-situ on the surface of substrates, such as various fabrics. The system mixes atomized streams of a monomer and a polymerization agent for the monomer in a mixing chamber where the polymerization reaction can start and then ejects droplets of the mixed monomer and a polymerization agent out of a nozzle and onto the substrate before the polymerization reaction is fully completed. The polymerization reaction can then complete after the droplets are on the substrate, thereby forming the electrically conductive polymer in-situ on the substrate. The system and process can be used to form electronic textiles that may form various wearable electronic components, such as sensors and luminescent strips, as part of wearable garments.

Abstract: Electronic textiles and methods of fabrication electronic textiles. Nanoparticles of a conductive material are sprayed along a conductive path into a fabric material so as to penetrate into the fabric. A layer of a second conductor material is coated over the nanoparticles along the conductive path. A layer of an insulator material is coated over the layer of the second conductor material so as to encapsulate the conductive path and form a trace. An electrode configured to contact a subject wearing the fabric material includes a layer of a third conductor material coated over the layer of the second conductor and electrically coupled with the conductive path. An electrical connector is secured to the fabric material and electrically coupled with the conductive path. The nanoparticles are sprayed onto the fabric material using a dual regime spray process implemented with a dual regime spray system.

Abstract: A flexible electrode device, including a typically thin film polymer layer, a typically thin film metal layer bonded to the polymer layer to yield a composite strip, and a polymer substrate ultrasonically welded to the composite strip to yield a flexible electrode device. The flexible electrode device exhibits electrical conductivity of at least 1.08×106 S·m?1, at least 60% tensile elongation, and less than 5% change in the R/R0 after 50 peeling cycles. The flexible electrode is formed without annealing and is formed under ambient pressure and temperature conditions. The flexible electrode device can have any convenient shape.

Abstract: Electronic textiles and methods of fabrication electronic textiles. Nanoparticles of a conductive material are sprayed along a conductive path into a fabric material so as to penetrate into the fabric. A layer of a second conductor material is coated over the nanoparticles along the conductive path. A layer of an insulator material is coated over the layer of the second conductor material so as to encapsulate the conductive path and form a trace. An electrode configured to contact a subject wearing the fabric material includes a layer of a third conductor material coated over the layer of the second conductor and electrically coupled with the conductive path. An electrical connector is secured to the fabric material and electrically coupled with the conductive path. The nanoparticles are sprayed onto the fabric material using a dual regime spray process implemented with a dual regime spray system.