Preparation and evaluation of polyester-cotton/wire blended conductive woven fabrics for electromagnetic shielding

Abstract

For the pursuit of conductive textiles with high electromagnetic shielding performance, specified yarns are processed with a special spinning feeding device with twist counts of 40 T, 50 T, 60 T, 70 T, 80 T, and 90 T, for Next, the optimal yarns from each group are made into SS/Pc-70 and Cu/Pc-80 conductive woven fabrics with a plain weave structure design. In addition, the surface resistivity, electromagnetic shielding effectiveness measurement and air permeability of the two conductive woven fabrics were tested and analyzed. Regarding the electromagnetic shielding performance test, the effects of the complete shielding network, the lamination layers of fabric, and lamination angle on the electromagnetic shielding performance are discussed. The test results indicate that Cu/Pc-80 woven fabrics has the lowest surface resistivity, which means it has the best electrical conductivity; Moreover, different types of metal wires provide the conductive fabrics with different levels of surface resistance. The variations in the lamination angles help attain a complete conductive network that significantly enhances the EMSE, and Cu/Pc-80 have a greater average shielding value comparatively and thus greater EMSE. For both types of conductive woven fabrics, one-layered conductive woven fabrics exhibit the maximal air permeability. As the air permeability of conductive woven fabrics is correlated with the thickness of fabrics, the greater the number of lamination layers, the lower the air permeability of the conductive fabrics.

Keywords

Metallic fiber electromagnetic shielding fabric shielding effectiveness fabric thickness lamination angles

Introduction

The rapid development of electronic technology paves the way for a widespread acceptance of the electronic productions and instruments, which subsequently leads to the ubiquitous presence of electromagnetic radiation. It is evitable that people are inflicted by the jeopardy caused by electromagnetic radiation. Electromagnetic radiation induces ill reactions in the human body from minor to severe levels, skin allergies, and cancers, the latter of which is due to the fact that electromagnetic radiation interferes with the immune system, damaging the cells and hampering the tissue recovery [1]. Nowdays, people have gained consciousness on healthy environmental protection increasingly, and thus pay more attention to develop EMSE textiles and shielding materials to decrease the hazards in the human body and instruments that are rendered by electromagnetic radiation. Accordingly, electromagnetic shielding technology and related products are constantly developed.

Electromagnetic shielding effectiveness means the function of a barrier that shields electromagnetic radiation, preventing it from harming the electronic applications, the environment, and the human body. The majority of electromagnetic shielding materials serve as a barrier to block and attenuate the incident electromagnetic waves, using highly conductive materials to reflect the electromagnetic radiation and attain EMSE effectively. While the electromagnetic radiation reaches conductive materials, a portion of electromagnetic waves are reflected, thereby decreasing the electromagnetic interference energy that penetrates the shield. The electromagnetic shielding effectiveness (EMSE) fabrics are divided into metal-coated fabrics, conductive coated fabrics, and metallic fiber blended fabrics. EMSE fabrics have advantages of a light weight, good flexibility, and easy processing, which qualify them a good candidate for EMSE use. Traditional EMSE materials are mainly composed of metallic materials that are heavy, expensive, and difficult to process [2,3]. For the acquisition of EMSE fabrics with excellent shielding performance, high value-added, and environmental protection, people fabricate EMSE fabrics with metallic fibers and ordinary fibers. Özkan and Telli combined stainless steel wires, copper wires, silver wires, and nylon yarns to fabricate wrapped yarns. Composed of wrapped yarns as the weft yarns, the resulting plain weave fabrics were analyzed in terms of structure and investigated for the influences of the aligned position of wrapped yarns, lamination layers of fabrics, metal types, and poling process on the EMSE and electromagnetic absorption/reflection effects [4]. Mofarah et al. studied the EMSE of woven fabrics that were made of Ag/PA/Co and Ag/PA-Co wrapped yarns, examining the effects of yarn count, core filament count, blended ratio, weft density, resistivity, yarn types, and wave frequency. It was proved that EMSE was highly dependent on the parameters of yarns and fabrics [5]. Erdumlu and Saricam compared the EMSE of single- and double-layered plain and twill conductive fabrics that were fabricated with cotton/copper composite yarns and cotton/stainless steel composite yarns. With a layered structure, cotton/stainless steel yarns provided the fabrics with greater EMSE in a broader incident frequency range [6]. Das et al. investigated the EMSE performance of stainless steel/polyester woven fabrics, and found that EMSE was proportional to the filling guide ratio of the weft yarns. Moreover, an increase in the stainless steel yarns or a greater number of lamination layers also had a positive influence on EMSE [7].

Duran and Kadolu studied the shielding characteristics of woven fabrics prepared by copper core yarn [8]. Mofarah et al. studied the preparation of copper/cotton cored yarn from copper wires with different diameters (0.06, 0.07, 0.08 mm) and the weaving of two knitted fabrics for electromagnetic shielding effectiveness tests [5]. Lou et al. studied the effect of fabric thickness and lamination Angle on electromagnetic shielding effectiveness [9]. Palanisamy et al. studied the preparation of conductive fabrics by blending different proportions of conductive components with polypropylene yarn, and analyzed the electromagnetic shielding properties, bending moments and air permeability of the fabrics [10]. Jai Veer and Kothari studied the metal type, proportion of conductive yarn and humidity that had significant effects on EMSE [11]. Safarova and Militký studied metal content, placement of conductive yarn, moisture content and its relationship with frequency [12]. Lou et al. explored that the four-layer conductive composite material was superposed at 0°/90°/0°/90°, and the electromagnetic shielding efficiency was the best, reaching 47.7 dB [13]. Ortlek et al. studied the influence of the direction, density and settlement type of conductive wrapped yarn on the electromagnetic shielding performance of fabrics [14]. Su and Chern studied the effect of fabric structure tightness on electromagnetic shielding effectiveness, and concluded that the plain weave has a higher EMSE than other weave [15]. Hwang et al. studied the effects of wire content, fabric layer number and layer Angle on the electromagnetic shielding effectiveness of fabrics [16]. Common shielded metals include silver, copper, nickel, chromium, stainless steel, and aluminum [17]. Stainless steel wires have advanced manufacturing techniques and a comparatively lower raw material cost, while copper wires demonstrate good electrical conductivity. Both are qualified EMSE materials for the uses required in high performance shielding occasions. In particular, plain weave fabrics exhibit the optimal EMSE because among other fabric, they possess the most flat and tidy surface, the length of the float and limited space among the yarns [18]. Therefore, it is difficult for electromagnetic waves to penetrate plain weave fabrics. Besides, EMSE of materials is in highly inverse proportion to the surface resistivity, the latter of which can be referred to predict the EMSE [19]. The combination of metallic ﬁbers and synthetic ﬁbers with speciﬁc techniques are used to prepare composite yarns, and then fabricated into EMSE fabrics, which possess merits, such as better EMSE, good durability, laundry resistance, high-temperature resistance, corrosion resistance, softness, air ventilation, and comfort [9]. The potential applications of conductive fibers or textiles in wearable devices are attractive. The preparation methods of conductive fabric include dipping method, in-situ polymerization method, mixing method, gas phase polymerization method, chemical transition method, etc., which are mainly used in sensors, electromagnetic shielding, electrostatic protection and other applications. Most electronic devices do already have electromagnetic shielding performance to protect them from interference and malfunctioning electromagnetic environments. However, there is almost no research on electromagnetic shielding in gas sensors.

In this study, Stainless steel/polyester cotton wrapped yarn and Copper/polyester cotton wire wrapped yarn were used as weft yarns to woven two kinds of conductive woven fabrics with plain weave structure. The test analyzes the morphology, mechanical properties, surface resistivity, electromagnetic shielding performance and air permeability of yarns and fabrics, compares and analyzes the influence of metal wire types, fabric thickness, lamination angle and other factors on the electromagnetic shielding effect of fabrics, and explores The influence of the number of fabric layers on the air permeability of the fabric is analyzed, and the conductive woven fabric with the best comprehensive performance is obtained. Finally, we apply the electromagnetic shielding fabric with the best comprehensive performance to the development of wearable gas sensors.

Experiments

Materials

316L stainless steel (SS, Yuaneng Co., Ltd., China) is an electrically conductive materials, which has a diameter of 0.06 mm. Copper (Cu, Jin Tong copper aluminum Co., Ltd., China) is an conductive materials, which has a diameter of 0.08 mm. Polyester cotton roving with a fineness of 452.8 tex, (Fujian Fengzhu Group Co., Ltd., China). T/C & CVC Yarns with a fineness of 32.13 tex, (Baoding Yuanlong Cotton Yarn Manufacturing Co., Ltd., China) , which has a diameter of 0.23 mm.

Preparation of wrapped yarn

A specified yarn feeding device (Figure 1) is used to wrap copper wires or stainless steel wires (core) in polyester cotton roving (wrap material), forming SS/Polyester cotton wrapped yarns and Cu/Polyester cotton wrapped yarns. The rotating speed is 3000 rounds/min; guide speed is 500 rounds/min; and the theoretical twist is 40, 50, 60, 70, 80, and 90 turns/10 cm. The direction of twisting is S twisting. Table 1 and Figure 2 separately show the specification and morphology of the wrapped yarns. The diameters of SS/Polyester cotton wrapped yarn and Cu/Polyester cotton wrapped yarn are 0.25 cm and 0.27 cm, respectively. After supplementary testing, the pore diameters of SS/PC-70 fabric and Cu/PC-80 fabric are 4.67 mm × 4.46 mm and 4.67 mm × 4.78 mm respectively.

Figure 1.

Schematic diagram of a specific spinning feeding device.

Table 1.

Specification of wrapped yarn.

Yarn code	Core yarn count (tex)	Breaking strength (N)	Tenacity (cN/dtex)	Elongation (%)
SS/Pc-40	62.40	7.47	1.19	9.30
SS/Pc-50	64.60	8.16	1.26	9.70
SS/Pc-60	65.16	9.34	1.43	10.00
SS/Pc-70	70.84	10.19	1.44	10.40
SS/Pc-80	71.80	9.64	1.34	9.90
SS/Pc-90	73.74	8.94	1.21	9.70
Cu/Pc-40	86.08	6.41	0.74	7.80
Cu/Pc-50	89.46	7.95	0.89	8.90
Cu/Pc-60	91.40	8.29	0.91	9.30
Cu/Pc-70	91.80	8.41	0.916	9.70
Cu/Pc-80	93.50	8.58	0.918	10.90
Cu/Pc-90	95.36	7.96	0.83	10.60

Figure 2.

(a) Asana microscope image of SS/PC-70 wrapped yarn (b) Asana microscope image of Cu/PC-80 wrapped yarn.

A semi-automatic weaving machine (DWL 5016, Hangzhou Tianma Textile Machinery Co., Ltd., China) is used to fabricate conductive woven fabrics with the proposed conductive yarn as the weft yarns and T/C & CVC Yarns as the warp yarns. The fabrics have a shrinkage rate of 7.1% and the specifications are presented in Table 2.

Table 2.

Characteristics of conductive woven fabrics.

Fabric code	Warp yarn	Weft yarn	Fabric weight (g/m²)	Thickness (mm)	Number of warp yarns (ends/10 cm)	Number of weft yarns (ends/10 cm)
SS/Pc	T/C & CVC Yarns	SS/Pc-70	124.34	0.42	143	131
Cu/Pc	T/C & CVC Yarns	Cu/Pc-80	127.45	0.45	145	134

Tests

Tensile test

As specified in the ASTM D2256, a universal force meter (HT-9101, Hong da Instrument, Taiwan) is used to measure the tensile properties (i.e. breaking strength and elongation at break) of yarns. The distance between clamps is 250 mm and the tensile rate is 300 mm/min, and the number of the samples was 20. The values were recorded for the mean.

Surface resistivity

As specified in the JIS L1094, a surface resistance test instrument (RT-1000, OHM-STAT, Static Solutions, USA) is used to measure the surface resistivity of conductive woven fabrics at 28.1°C and relative humidity of 77.2%. Samples are mounted on an insulating plate while a five-pound weight is loaded in the tester in order to keep both parallel electrode plates in good contact with samples. Twenty samples for each specification are tested to have the mean.

Electromagnetic shielding effectiveness

As specified in the ASTM D4935-10, an EMI shielding analyser (E-Instrument Tech, Taiwan) and a spectrum analyzer (Advantest R3132, Burgeon Instrument, Taiwan) are used for the EMSE measurement. Samples have a size of 120 mm × 120 mm and the incident electromagnetic waves are between 300 KHz and 3000 MHz. Figure 3 illustrates the laminating angle for three-layered fabrics, which can be used as a reference for other groups of various numbers of lamination layers.

SE = 10 log [\frac{P_{1}}{P_{2}}]

(1)

where P₁ is the received power with the conductive fabrics present and P₂ is the received power without the conductive fabrics present. Figure 4 shows the specimen dimensions for reference and load test [20].

Figure 3.

Lamination angle of the conductive woven fabrics laminated at 0°/0°/0°, 0°/90°/0°, and 0°/45°/90°.

Figure 4.

Specimen dimension for reference (left) and load test (right).

Air permeability

As specified in the ASTM D0730, an air permeability tester (Digital fabric gas permeability meter, YGB461D Wenzhou Darong Textile Co., Ltd., China) is used to measure the air permeability at a pressure difference of 200 Pa. Samples have a size of 25 cm × 25 cm and 10 samples for each specification are tested in order to have the mean.

Results and discussion

Mechanical properties of wrapped yarns

Figure 5(a) and (b) respectively show the tensile breaking performance of SS/Pc and Cu/Pc the prepared two kinds of wrapped yarns. As can be seen from Figure 5, SS/Pc-70 and Cu/Pc-80 wrapped yarns have the highest breaking strength and elongation at break. The tenacity of the two types of wrapped yarns, SS/Pc and Cu/Pc, both show an upward trend with the increase of twist. Afterwards, when the twist reaches a certain degree saturation, the tenacity of wrapped yarns starts decreasing with the increase in twist. The main reason is that twisting process combines polyester cotton roving and metallic wires firming with a compact structure, and meanwhile the cohesion is also improved. The content of polyester cotton roving and metal wire per centimeter increases, which can increase strength and elongation at break of wrapped yarns. However, when over-twisting, the axial component force of the wrapped yarn is reduced, resulting in a decrease in mechanical properties. Therefore, through the comparison of the coated state and mechanical properties of the two kinds of wrapped yarns, in the next experiment we choose SS/Pc-70 and Cu/Pc-80 conductive wrapped yarns are used for the weaving conductive woven fabrics.

Figure 5.

Tenacity and elongation of the prepared wrapped yarns.

Surface resistivity of conductive woven fabrics

Using a surface resistance tester to test the surface resistivity of the two conductive woven fabrics, the test results are shown in Figure 6. It can be seen from Figure 6 that conductive woven fabrics of different types of wire have different surface resistivity. where different metal wires provide conductive woven fabrics with different levels of surface resistivity [12]. Cu/Pc-80 conductive woven fabrics exhibit a comparatively lower surface resistivity of 3.15 ohm/sq, the main reason is that copper wire (Cu) has better conductivity than stainless steel wire (SS).In addition, this can also be verified from Figure 2. It can be seen from Figure 2 that the larger the diameter of the feed wire, the more difficult it is to completely cover it, the easier it is to bare on the surface of the fabric, and the smaller the surface resistivity of the conductive woven fabric. Moreover, the surface resistivity of conductive woven fabrics is inversely proportional to the conductivity, the smaller the surface resistivity, the better the conductivity of fabrics, and theoretically the better the EMSE effect.

Figure 6.

Surface resistivity of the two conductive woven fabrics.

Influence of fabric layers on EMSE of conductive woven fabrics

EMSE means using shielding materials with high conductivity and high permeability as a barrier in order to attenuate the incident electromagnetic waves, the energy of which is attenuated [21]. Electromagnetic shielding performance (dB) of SS/Pc-70and Cu/Pc-80 woven fabrics is tested as related to the lamination layers of fabrics as Figure 7(a) and (b), respectively. One-layered SS/Pc-70 and Cu/Pc-80 woven fabrics have highest EMSE of 9.57 dB and 9.64 dB, while six-layered SS/Pc-70 and Cu/Pc-80 woven fabrics have highest EMSE of 12.15 dB and 13.82 dB, respectively. In the low frequency 200–700 MHz, with the increase of the lamination layers of fabric, the shielding value of the two conductive fabrics has a subtle increase. According to the Schelkunoff electromagnetic shielding theory, the electromagnetic wave pass through the shield and generates energy loss and attenuates. The energy loss can be divided into two manners: reflection loss, When propagating in a shielding material, a part of the energy is converted into heat, resulting in a loss of electromagnetic energy. Furthermore, as the lamination layers of the fabric increases, the incident depth of electromagnetic waves increases, and the electromagnetic intensity decays exponentially. The single-layered shield has two interfaces which render incident electromagnetic waves with reflection loss two times and absorption loss one time. Accordingly, it is required to go through four interfaces when incident electromagnetic waves enter a two-layered shield, which means reflection loss four times and absorption loss two times. On the other hand, when electromagnetic waves propagate in the interior of a shield, there is a portion of the incident waves being transformed into heat that is another manner to attenuate the electromagnetic energy. Finally, with a rise in the thickness of the fabrics, there is a greater incident depth presented, which in turn debilitates electromagnetic intensity in an index relationship [22].

Figure 7.

EMSE of conductive fabric as related to varying numbers of lamination layers (1-6). The lamination angle is 0°/0°/0°/0°/0°/0°.

Effect of lamination angle on EMSE of conductive woven fabrics

An adjustment in lamination angle of the conductive fabrics help forming a complete shielded network, which benefits the EMSE performance [23]. Comparing to a lamination an angle of 0°/0°/0°/0°/0°/0°, the lamination angle of 0°/90°/0°/90°/0°/90 provides SS/Pc- 70 and Cu/Pc-80 woven fabrics with EMSE of 38.15 dB and 39.3 dB, respectively, as Figure 8（a）和（c）. In addition, Figure 8(b) and (d) respectively show that with a lamination angle of 0°/45°/90°/-45°/0°/45°, the EMSE is 33.61 dB for SS/Pc-70 and 37.88 dB for Cu/Pc-80 woven fabrics. Based on the fluctuation degree of the curve in the figure, the lamination angle of 0°/90°/0°/90°/0°/90°demonstrates better shielding effectiveness against electromagnetic waves. It can be concluded from the data that changing the lamination angle has a greater impact on the electromagnetic shielding effectiveness at high frequencies. Therefore, variations in lamination angle help fabrics to form a complete shielded network with more interlacing points of warp and weft yarns. The pore sizes are the smallest accompanied with a significant decrease in porosity, so the transmittance of electromagnetic waves is compromised, which remarkably improves the EMSE of SS/Pc-70 and Cu/Pc-80 woven fabrics. To sum up, the majority of electronic products requires the shielding material to be capable of blocking incident electromagnetic waves ranging of 30–1000 MHz and attains EMSE of 35 dB, which is deemed qualified and effective against electromagnetic waves. Therefore, the proposed conductive fabrics can offer suitable EMSE protection for industrial or commercial electronic equipment.

Figure 8.

EMSE of conductive fabrics as related to laminating angles: (a) and (c) the lamination angle is 0°/90°/0°/90°/0°/90° and (b) and (d) the lamination angle is 0°/45°/90°/-45°/0°/45°.

Air permeability of conductive woven fabrics

Air permeability is an important parameter for thermal comfort. When heat and perspiration are generated from body, it helps to exchange the air (Ballou, 1954) [24]. Figure 9 shows the air permeability of electromagnetic shielding fabrics as related to the lamination layers of fabrics. Regardless of the fabric types, single-layered fabrics demonstrate the optimal air permeability that meets the clothing requirements. The air permeability of Cu/PC-80 and SS/PC-70 woven fabrics in a single layer was 3825 cm³/S/cm² and 3716 cm³/S/cm² respectively. At 1–2 layers, the air permeability of SS/PC-70 woven fabrics is lower than that of Cu/PC-80 woven fabrics, which may be due to the lower cover factor of Cu/PC-80 fabrics and the better the air permeability. According to the data, the air permeability of conductive woven fabrics is related to the number of lamination layers of fabrics, and varies with the number of lamination layers of fabrics (1–8 layers). As it increases, the air permeability of the conductive fabrics gradually decreases. Moreover, when the number of lamination layers is 8, both fabric types have almost the same air permeability that is lower than 900 cm³/S/cm². The reason is that when the number of layers increases, the thickness of the fabric will increase and the density will be relatively tight, resulting in less air molecules permeating, so the air permeability of the fabric will decrease.

Figure 9.

Air permeability of the conductive woven fabrics with different numbers of laminating layers (1–8 layers).

Conclusion

This study successfully produces the conductive wrapped yarns with different twists and the corresponding conductive woven fabrics. The surface morphology and mechanical properties of wrapped yarn are investigated, determining the two optimal wrapped yarns. The tensile properties of SS/Pc and Cu/Pc wrapped yarns are dependent on the wrapping counts, especially SS/Pc-70 and Cu/Pc-80 that gain the maximal breaking strength and elongation at break. Tensile properties increase with the wrapping counts, whereas over-wrapping leads to a decrease in the properties. In addition, different metal wires have varying levels of surface resistivity. In particular, Cu/Pc-80 woven fabric have the lowest surface resistivity and thus the highest conductivity. Moreover, as the number of lamination layers of fabric increases, the shielding value of the two conductive fabrics has shown an upward trend. Variations in lamination angle help form a complete shielding network, improving EMSE considerably. A lamination angle of 0°/90°/0°/90°/0°/90° provides both types of conductive woven fabric with higher EMSE. And overall, the electromagnetic shielding performance of Cu/Pc-80 is better. The two kinds of electromagnetic shielding fabrics have the best air permeability in a single layer, which can fits the requirement of clothing, but the air permeability decreases significantly when there are increasingly more lamination layers. Among them, Cu/Pc-80 woven fabrics have air permeability of 3825 cm³/S/cm² in a single layer. Therefore, through the comparison of the coated state and mechanical properties of the two kinds of wrapped yarns, the electromagnetic shielding effectiveness and air permeability of the two kinds of conductive woven fabrics are compared at the same time. In general, the comprehensive performance of the Cu/Pc-80 conductive fabric better. We want to improve the conductivity of the fabric through in-situ polymerization in the next experiment, and hope it can be used in the development of gas sensors, so as to promote the practical application of textile-type gas sensors.

Footnotes

Declaration of conflicting interests

The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Funding

The author(s) received no financial support for the research, authorship, and/or publication of this article.

ORCID iDs

Ching-Wen Lou

Jia-Horng Lin

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