Müslüm Kaplan

1. The textile industry faces increasing pressure to respond rapidly to market demands while maintaining cost efficiency in product development. A critical challenge in this process is the creation...

This study investigates the development of electrically conductive polyamide 6 (PA6) composite filaments incorporating carbon black (CB) for smart textile applications. The effects of CB content (5–10 wt%) and processing parameters on electrical, rheological, and mechanical properties were systematically evaluated. While bulk composites achieved percolation at ~ 2.5 wt% CB, fiber formation required higher loadings to maintain conductivity due to processing-induced network disruption. Rheological analysis revealed that increasing CB content enhanced shear-thinning behavior, with viscosity ranging from 10 ² Pa s (5 wt% CB) to 10 ⁴ Pa s (10 wt% CB). Processing parameters significantly influenced CB distribution and network formation, particularly winding speed (up to 250 m/min) and throughput (0.80–0.95 cm ³ /min). The 7.5 wt% CB composition emerged as optimal, providing sufficient conductivity while maintaining acceptable processability. This systematic correlation between rheological behavior and electrical performance establishes fundamental design principles for conductive polymer fiber production with tunable properties. These findings provide a comprehensive framework for developing conductive PA6/CB filaments with tunable properties for smart textile applications and scalable industrial production.

Melt‐spun electrically conductive polymer fibers often face trade‐offs among conductivity, mechanical strength, and processability. This study introduces a synergistic SWCNT/carbon black (CB) hybrid strategy where spherical CB particles appear to maintain connectivity within aligned SWCNT networks. PA6 composites with optimized ratios (PA6/1% SWCNT/3% CB) were systematically characterized for electrical, rheological, thermal, and processing behavior. Percolation thresholds (φc, SWCNT ≈ 0.1–0.25 wt.%, φc, CB ≈ 2–2.5 wt.%) confirmed the superior efficiency of SWCNTs in network formation. The hybrid system maintained resistivity of ∼10 ² –10 ⁴ Ω·cm despite drawing (DDR 2–4), while single‐filler SWCNT systems failed (>10 ⁹ Ω·cm). Complex viscosity (∼1400 Pa·s at 270°C) remained within processable ranges despite elevated values, exhibiting stable shear‐thinning behavior. Mechanical properties showed tenacity of 4–6 cN/dtex with 100%–150% elongation. These structure‐property relationships demonstrate the potential of hybrid nanofiller systems for producing conductive filaments suitable for smart textile applications, positioning hybrid SWCNT/CB systems as promising candidates for scalable smart textile manufacturing.

Smart textiles require conductive polymer filaments that balance electrical performance with industrial processability. This study presents a hybrid nanofiller approach combining branched carbon nanotubes (bCNTs) and carbon black (CB) in polyamide 6 (PA6), enabling scalable melt spinning of high‐performance conductive filaments. Comparative analysis of PA6/bCNT, PA6/CB, and PA6/bCNT/CB systems established structure–property–processing relationships essential for smart textile applications. Rheological characterization reveals that the hybrid system merges the strong conductive network of bCNTs with the improved spinnability provided by CB, ensuring industrial‐scale processability. The optimized PA6/3 wt.% bCNT/3 wt.% CB composite achieved low resistivity (≈50 Ω·cm) while maintaining stable spinning at winding speeds up to 1000 m min ⁻¹ . A structural evolution model is proposed, showing how CB particles act as bridging agents between aligned bCNTs, stabilizing conductive pathways under high draw ratios. Complementary microscopy, thermal, and mechanical analyses validated this mechanism and confirmed the balance of conductivity, thermal stability, and mechanical performance. By integrating material design, process optimization, and functional validation, this work overcomes key barriers limiting commercial conductive filaments. The developed hybrid technology offers cost‐effective, scalable solutions for next‐generation smart textiles in wearable electronics, strain sensing, and electromagnetic shielding.

The development of electrically conductive polymer filaments has gained significant attention for applications in smart textiles and flexible electronics. This study systematically investigates the influence of different carbon black (CB) grades and their hybridization with multiwall carbon nanotubes (MWCNTs) on the electrical and processing properties of polyamide 6 (PA6) based nanocomposite filaments. Three commercial CB grades were evaluated through morphological analysis, mixing energy measurements, and electrical resistivity characterization. Light microscopy analysis revealed that Vulcan XC72 exhibited superior dispersion homogeneity compared to XC MAX22 and XC615. The mixing energy calculations demonstrated that XC72 maintained consistent processing behavior, with energy requirements ranging from 25.067 J/cm³ at 1 wt% to 25.790 J/cm³ at 5 wt% loading. Electrical resistivity measurements showed significant differences in percolation behavior, with XC72 achieving 2.33E+03 ohm·cm at 13 wt%. Based on these findings, XC72 was selected for developing PA6/CB and PA6/MWCNT/CB hybrid nanocomposite filaments. While PA6/CB filaments showed insufficient conductivity, PA6/MWCNT filaments achieved 2.94E+00 ohm·cm at 10 wt%, and hybrid filaments demonstrated intermediate conductivity of 7.28E+00 ohm·cm. SEM analysis revealed the formation of interconnected networks where MWCNTs effectively bridged CB particles, explaining the enhanced conductivity of hybrid systems. This study provides crucial insights for developing cost-effective conductive polymer filaments through systematic filler selection and processing optimization.

Bu çalışmada, tekstil endüstrisinin Ar-Ge ihtiyaçları ve eğitim kurumlarının uygulamalı eğitim gereksinimleri için elektronik jakarlı numune dokuma makinesi tasarlanmış ve prototip imalatı gerçekleştirilmiştir. 192 kancalı elektronik jakar modülleri kullanılan prototipte, her kancaya 5 harniş bağlanarak maksimum 67,5 cm dokuma eni elde edilmiştir. Makine tasarımında TS EN ISO 12100:2010 standardı kapsamında kapsamlı risk değerlendirmesi yapılmış, mekanik ve elektronik güvenlik önlemleri alınmıştır. Geliştirilen prototip, yurtdışı menşeli benzer makinelere göre düşük maliyet avantajı sunarken, 785W elektrik tüketimi ile ekonomik işletme koşulları sağlamaktadır. Sistem tasarımı, kanca sayısının ve dokuma eninin müşteri taleplerine göre modifiye edilebilmesine imkan vermektedir. Ticarileşebilir nitelikte olan prototip, tekstil endüstrisinin Ar-Ge çalışmalarına ve eğitim kurumlarının uygulamalı eğitimlerine katkı sağlayabilecek özelliktedir.

Bu çalışmada, jakarlı dokuma makinelerinde ağızlık yüksekliğinin kumaş eni boyunca uniform dağılımı için gerekli jakar kulesi yüksekliğinin belirlenmesine yönelik geometrik bir analiz gerçekleştirilmiştir. Harniş kablolarının platin yatağından harniş tablasına kadar olan eğimli yolu, jakar yüksekliğinin önemli bir tasarım parametresi olduğunu göstermiştir. Yapılan analizlerde, farklı kumaş enleri (20-200 cm) için jakar yüksekliğinin (25-200 cm) ağızlık geometrisine etkisi incelenmiştir. Yapılan analizler, ağızlık yüksekliğinin uniform dağılımı için jakar kulesi yüksekliğinin kumaş eni ile doğrudan ilişkili olduğunu ve kumaş enine göre optimum değerlerde seçilmesi gerektiğini göstermiştir. Bu geometrik analiz, 192 kancalı ve maksimum 67,5 cm dokuma enine sahip bir elektronik jakarlı numune dokuma makinesinin tasarımında kullanılmıştır. Her kancaya 5 harniş bağlanarak toplamda 960 çözgü ipliğinin kontrolü sağlanmıştır. Geliştirilen prototipte 67,5 cm dokuma eni için jakar kulesi yüksekliği 120 cm olarak belirlenmiş ve merkezden en uzak noktadaki ağızlık yüksekliği 4,31 cm olarak hesaplanmıştır. Bu çalışmada sunulan geometrik analiz ve tasarım parametreleri, farklı kumaş enlerinde çalışacak jakarlı dokuma makinelerinin tasarımında temel alınabilir.

This study presents the development of high‐performance poly(vinylidene fluoride) (PVDF) based piezoelectric nanocomposites incorporating branched carbon nanotubes (bCNTs) and zinc oxide nanowires (ZnO NWs) through a scalable melt mixing process. ZnONWs with uniform morphology (mean diameter: 36.5 nm) are successfully synthesized and characterized. FTIR analysis confirms that incorporating bCNTs into PVDF significantly enhances the β‐phase content, while adding ZnO NWs (1–10 wt.%) resulted in progressive intensification of β‐phase characteristic peaks, with higher ZnO content showing stronger electroactive phase formation. The optimized composition (PVDF/0.5 wt.% bCNTs/5 wt.% ZnO NWs) demonstrates superior piezoelectric performance with a power density of 5.62 µW cm⁻², voltage output of 1.55 V, and current output of 14.48 µA. Moreover, the composite exhibits excellent mechanical properties with a tensile strength of 48 MPa and maintains stable performance under cyclic loading. The enhanced performance is attributed to the synergistic effect between bCNTs and ZnO NWs, optimal β‐phase formation, and efficient charge transfer pathways. This study demonstrates the potential of melt‐mixed PVDF nanocomposites for practical energy harvesting applications.