Influence of Yarn Linear Density and Weave Interlacement on the Dynamic Response of Woven Temperature Sensors

Abstract

The integration of conductive yarns into woven fabrics offers a promising route to flexible, durable, and scalable temperature sensors. In this study, silver-coated yarns with varying ply levels (1-ply, 2-ply, and 4-ply) were systematically incorporated into plain and twill woven structures to investigate the influence of yarn linear density and weave interlacement on sensor performance. The developed sensors were evaluated for resistance–temperature response within 30–60 °C using a digital multimeter and controlled oven setup. Results indicate that plain weave structures demonstrated higher sensitivity (?R/R up to 5.1%) but moderate linearity, while twill weave structures provided lower sensitivity (?R/R as low as 1.01%) but superior linearity (R² up to 0.9966). Increasing ply levels reduced sensitivity but improved repeatability and stability. These findings highlight a trade-off between sensitivity and stability, offering design guidelines for tailoring textile-based temperature sensors to specific applications. The outcomes support future development of smart and sustainable textile composites for healthcare, structural health monitoring, and industrial applications.