This graduation project set out to design a modular interconnection system for smart textile applications for Elitac Wearables, that is widely implementable, robust, durable, cleanable,cost-effective, more integrated in the textile carrier and ergonomically t
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This graduation project set out to design a modular interconnection system for smart textile applications for Elitac Wearables, that is widely implementable, robust, durable, cleanable,cost-effective, more integrated in the textile carrier and ergonomically to wear. The Double Diamond Design Process methodology of the Design Council (2015) is adjusted to a 4 phase Diamond Design process to guide the process towards a final embodiment design. Phase 1. Understanding the problem: In this phase the focus lies on finding the key challenges Elitac Wearables is facing when designing smart textile wearables. The challenges identified are: the lack of proper integration of electronics & the textile carrier, and no robust and durable (inter-)connections. Furthermore, cable management poses a real challenge as classic electrical wiring is used. A fourth challenge is the cleanability and waterproofing of designs, allowing them to be laundered by users. Also, products are not fit for mass production due to the lack of scalable production processes, the availability of parts for longer periods of time and high prices. All findings were summarised in a problem definition and a program of requirements & wishes. Phase 2. Finding building blocks for haptic feedback systems: Technology literature research and practical tests are conducted to select technologies that can help solve the problems found in design phase one. The technologies are rated on mechanical properties,conductive properties, processability, stretchability, flexibility, durability,and costs. High potential technologies I selected during this research range from wire connections, electrical connections, integration techniques from electronics & textiles and removeable Furthermore, in this study, the solution has been divided into four modules: The tactor (containing an ERM and a driver PCB), the power & data transport (interconnecting all electrical modules), the main controller (containing the micro controller and power supply) & the textile carrier (which makes the technology wearable). Phase 3. Mounting haptic feedback systems to garments: Multiple concepts are generated of which two are selected: The first concept is based on conductive yarn knitted pockets & conductive Velcro as connector while the second concept implements sewn conductive yarn traces and a pogo pin connector. First tests show good data reliability and launderability properties. In the end a hybrid version of the two concepts is chosen. Phase 4. Embodiment design of the haptic feedback system: The final embodiment design implements a power and data transport system consisting of 4 non-isolated sewn conductive yarn traces to enable I2C communication. The waterproof and overmolded tactor module integrates 4 conductive strips, that are pressed against the conductive yarn traces inside pockets as electrical connection. The main control module is connected through a magnetic male pogo pin connector. An overmolded landing spot with the female pogo pin connector acts as easy attachment point for the main module. A functional prototype powers 3 tactor modules at the same time and user tests show a high level of comfort, but also room for improvement of the interaction when placing the tactor modules inside the pockets and the size of the main module. When reconsidering the goal of this graduation project (the design a modular interconnection system for smart textile applications for Elitac Wearables, that is widely implementable, robust,durable cleanable, cost-effective, more integrated in the textile carrier and ergonomical to wear), the design fulfils most of the requirements. The final design scores well on the following design drivers: widely implementable, scalable, cost effective and cleanable. However, the robustness and durability of the design is still questionable when it comes to corrosion of conductive yarns caused by artificial sweat. The wire fragmenting is also something that will need to be prevented in future designs. Moreover, the ergonomics of a prototype of the design is rated to be comfortable during user tests as it does not restrict participants in their movement and the electrical modules are barely noticeable. Though some aspects of the interaction require improvement.