Manufacturing and Performance Assessments of Several Applications of Electrotextiles and Large-Area Flexible Circuits

ABSTRACTNumerous applications of electrotextiles and flexible circuits have been identified that can advance systems performance for many commercial, military, and aerospace devices. Several novel uses of electrotextiles have been developed for lab testing, while others have been utilized in products on the commercial market, as well as items that have flown in space. ILC Dover, Inc. has utilized conductive fibers in various inflatable and tensile structures for signal transmission and electrostatic charge protection. Conductive and pressure sensitive textiles have been incorporated in the advanced development space suit (I-Suit) as switch controls for lights and rovers, and as signal transmission cables. Conductive fibers have been used in several stitched applications for electrostatic charge dissipation. These applications include large pharmaceutical containment enclosures where fine potent powders are being captured for transfer between manufacturing facilities, as well as impact attenuation airbags used in landing spacecraft on the surface of Mars. In both cases, conductive threads are uniquely located in seams and panel locations to gather and direct charge through surface fibers and panel interconnects. Conductive fibers have also been utilized in a conformal Sensate Liner garment for the identification of wound locations and medical sensor signal transmission for soldier health monitoring while on the battlefield. The performance challenges of these structures require a careful, systematic application of electrotextiles because of the flexing, straining, and exposure of the materials to harsh environments. ILC has also been developing “gossamer” spacecraft components utilizing unique materials and multi-functional structures to achieve extremely low mass and low launch volumes. Examples of large deployable structures featuring very thin, large flexible circuits for use in space include synthetic aperture radar (SAR) antennas, communications antenna reflectarrays, and active variable reflectance solar sails. Design and materials challenges of electrotextile and large-area flexible circuit membrane structures as demonstrated in engineered applications will be discussed in this paper.