Development of Low-Resistance Conductive Threads from E-Waste for Smart Textiles

Conductive thread is an integral aspect of smart textiles in the domain of electronic textiles (e-textiles). This study unveils the development of twelve distinct variants of conductive threads using twisting method, the fusion of copper filament with cotton and polyester threads. The threads are coated with a carbon paste solution enriched with dissolved sea salt. The carbon paste is obtained from non-functional dry cell batteries, conventionally categorized as hazardous electronic waste (e-waste), that underscores an economically viable and environmentally sustainable approach. Experiments proved that each variant demonstrates minimal electrical resistance. Comparative analysis against commercially available conductive threads on the market reveals a significant performance advantage. Notably, the ‘Carbon Coated Cotton Twisted Copper Thread-II’ showcases a record low resistance of 0.0164 Ω cm-1 which is approximately 19.39 times lower than the most efficient counterpart, ‘Bekinox VN type (12/1x275/100z)’. Further investigation also demonstrates the integration of these conductive threads into fabric-based flexible circuits marking a significant advancement in e-textiles. Future avenues of research may focus on optimization strategies for fabricating conductive threads and exploring their diverse applications in wearable technology and smart textiles, thus catalyzing further progress in the field.