Aluminum-Foil/Polyester Core-Spun Yarns Conductive Fabric Enabling High Electromagnetic Interference Shielding

Area of Science:

• Materials Science
• Electrical Engineering
• Textile Engineering

Background:

• Electromagnetic pollution is increasing due to electronic devices and wireless systems.
• Traditional metal shielding materials have limitations like weight, flexibility, and cost.
• High-performance electromagnetic interference (EMI) shielding materials are needed.

Purpose of the Study:

• To design and fabricate novel conductive fabrics for EMI shielding.
• To evaluate the performance of these fabrics, focusing on electrical and shielding properties.
• To address the limitations of conventional shielding materials.

Main Methods:

• Core-spun yarns were fabricated with polyester core and aluminum-foil outer layer.
• Three conductive fabrics with varying structural parameters were woven.
• Surface morphology, air permeability, electrical conductivity, and EMI shielding effectiveness were systematically investigated.

Main Results:

• DT5W27 fabric exhibited optimal performance: 2722.64 S·m⁻¹ conductivity, 37.29 dB shielding effectiveness, and 99.99% attenuation rate.
• The fabric maintained high shielding performance after 100 bending/twisting cycles and exposure to pH 3-9 solutions.
• The fabrication process is facile and low-cost.

Conclusions:

• The developed conductive fabrics offer a flexible, durable, and cost-effective alternative to traditional EMI shielding materials.
• DT5W27 demonstrates excellent electrical conductivity, mechanical durability, and chemical stability.
• These materials show significant potential for applications in protective clothing and lightweight shielding solutions.