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

## TL;DR

This paper introduces a lightweight, flexible conductive fabric made of aluminum-foil wrapped polyester yarns that effectively shields against electromagnetic interference.

## Contribution

A novel core-spun yarn design combining polyester and aluminum-foil for high-performance, durable EMI shielding fabric.

## Key findings

- DT5W27 fabric achieved 37.29 dB shielding effectiveness and 99.99% electromagnetic wave attenuation.
- The fabric retained performance after 100 bending cycles and exposure to pH 3–9 solutions.
- The fabrication method is simple, low-cost, and suitable for protective clothing and lightweight shielding.

## Abstract

With the rapid advancement of modern electronic devices and wireless communication systems, electromagnetic pollution has become a prominent issue, prompting the development of high-performance electromagnetic interference (EMI) shielding materials. Although traditional metal shielding materials exhibit excellent conductivity, there are many limitations such as high weight, poor flexibility, susceptibility to corrosion, and high cost. To overcome these challenges, in this study, we design and fabricate core-spun yarns using polyester filaments as the core and an aluminum-foil-wrapped layer as the conductive outer component, and further weave them into three conductive fabrics with different structural parameters. Through systematic investigation of their surface morphology, air permeability, electrical properties, and EMI shielding performance, DT5W27 demonstrates optimal overall performance: electrical conductivity of 2722.64 S·m−1, shielding effectiveness of 37.29 dB, and electromagnetic wave attenuation rate of 99.99%. Specifically, even after 100 bending, twisting cycles, and exposure to solutions with pH values ranging from 3 to 9, the fabric maintains high shielding performance. The fabrication process is facile and low cost, and these composites have good flexibility, outstanding EMI shielding performance, exceptional mechanical durability, and chemical stability. These advantages make them have broad application potential in protective clothing and lightweight shielding materials.