(A) study on the interconnection of copper threads and metal plates using an ultrasonic welding method for electronic textile applications

Abstract

Interconnection method for snap type detachable batteries is an indispensable technology to complete the wearable electronics system on clothes. Ultrasonic welding, the way to make a metallurgical bonding by applying lateral vibration, is a promising candidate for joining metal snap buttons and conductive threads sewn on fabric to make connection sites for batteries. To investigate the potential of ultrasonic welding for interconnection between the snap button and the conductive thread, effect of basic welding parameters was investigated and optimized using 90-degree peel test. Brass snaps and polymer coated copper wires were welded using optimized welding parameters and the welded joint was evaluated. The brass snaps and copper threads were successfully welded, and the welded joints showed excellent electrical properties (including contact resistance and power handling capability), and washing reliability than just physically contacted joints. This ultrasonic welding method can be applied to interconnect the wearable and washable electronics to make stable joints.