Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

Mukesh Kumar Singh; Gaurav Saraswat; Samrat Mukhopadhyay; Himangshu B Baskey

doi:10.1177/15280837211062054

Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

Singh, Mukesh Kumar; Saraswat, Gaurav; Mukhopadhyay, Samrat; Baskey, Himangshu B 2022-06-01 00:00:00 Electromagnetic shielding (EMS) has become the necessity of the present era due to enormous expansion in electronic devices accountable to emit electromagnetic radiation. The principal target of this paper is to originate three-dimensional (3D) orthogonal fabrics with conductive hybrid weft yarn and to determine their electromagnetic shielding. DREF-III core-spun yarn using copper ﬁlament in the core and polyphenylene sulﬁde (PPS) ﬁber on the sheath and fabric constructed of such yarn has a promising elec- tromagnetic shielding characteristic. Box–Behnken experimental design has been em- ployed to prepare various samples to investigate the electromagnetic shielding efﬁciency of 3D orthogonal woven structures. The orthogonal fabric samples were tested in an electromagnetic Ku frequency band using free space measurement system (FSMS) to estimate absorbance, reﬂectance, transmittance, and electromagnetic shielding. The increase in copper core ﬁlament diameter and hybrid yarn linear density enhances the EMS of orthogonal fabric. Statistical analysis has been done to bring out the effect and interaction of various yarn and fabric variables on EMS. Metal ﬁlament diameter, ori- entation, sheath ﬁbers percentage, and fabric constructional parameters signiﬁcantly affected electromagnetic shielding efﬁciency. The inferences of this study can be applied in Uttar Pradesh Textile Technology Institute, Souterganj Kanpur, India Department of Textile and Fibre Engineering, IIT Delhi, New Delhi, India DMSRDE, GT Road Kanpur, India Corresponding author: Mukesh Kumar Singh, Uttar Pradesh Textile Technology Institute, 11/208 Souterganj, Parwati Bagla Road, Kanpur 208001, India. Email: mukesh70ster@gmail.com Singh et al. 6667S other 3D structures like angle interlock, spacer fabrics for curtains, and coverings for civilians and military applications. Keywords Conductive yarns, electromagnetic shielding, orthogonal structure, polyphenylene sulﬁde, reﬂectance, transmittance Introduction The EMS is required to shield electrical and electronic assemblies from external elec- tromagnetic (EM) ﬁelds. The electromagnetic shielding fabric (ESF) has inherent and soft functionalities which have found comprehensive application in civilian, industrial, and army-related electromagnetic shielding. The effect of yarn type, weave type, and fabric thickness on EMS was studied a little on two-dimensional fabrics. The fabric weave, an interlacement pattern of warp and weft thread containing conductive materials, is a crucial factor in inﬂuencing the shielding effectiveness (SE) of ESF in two-dimensional fabrics. 2–4 The plain weave fabric was found better than the twill weave fabric for EMS. The thread density and number of apertures do not effectively regulate the SE of metallic yarn- containing fabrics. The coarser yarns are found more effective in SE of EMS fabrics. With an enhancement in warp and weft density with the number of conductive fabric layers, an increase in EMS is witnessed in 3/1 twill copper fabrics. Copper is found more effective than brass in EMS fabric manufacturing. An effective physical model was developed to predict the SE of EMS fabrics by considering lateral longitudinal yarn, conductive ﬁbers, and yarn diameter as input 7 8 parameters. The metal ﬁber content per unit area has enhanced SE in EMS fabrics. The effect of the copper content in copper/glass knitted polypropylene composite, linear yarn density, and stitch density is studied for electromagnetic shielding and shielding effectiveness. Metal and polyester ﬁlaments are used to produce a metallic grid in conductive fabrics. The study concludes that electromagnetic shielding effectiveness (EMSE) increases with metal content and the square grid structure. The cotton/copper hybrid yarns possess higher EMSE than cotton/stainless steel hybrid yarns fabric without a signiﬁcant effect of weave. Silver coated cotton yarn and silver core-sheath ring yarns produce single jersey knitted fabric for electromagnetic shielding. The fabric produced by the plating technique shows higher EMS than core-spun yarn knitted fabrics at low-frequency regions. A mathematical model also found a high degree of correlation between predicted and measured EMS values in metallic hybrid yarn-based 2D fabrics when metal yarn di- ameter, metallic yarn periodic spacing, electric conductivity, electromagnetic wave polarization direction, and the weaving angle were considered as input parameters. The plain-woven 2D fabric samples manufactured by core-sheath stainless steel/polyester yarn were exhibited that the direction of hybrid yarns and warp-weft yarn densities affects the SE of EMS fabrics. 6668S Journal of Industrial Textiles 51(4S) Polyphenylene sulﬁde (PPS) ﬁber/copper particles composites have been successfully utilized to manufacture electrical conductive fabric. However, PPS did not cover copper wire as sheath material for EMS purposes although copper wires were used to develop 15,16 textile-based sensors and actuators. PPS staple ﬁber, a semi-crystalline thermoplastic material selected to cover the copper monoﬁlament using the DREF-III spinning process, has found versatile applications due to its outstanding electrical, tensile, and thermal applications, and inherent ﬂame retardant 17,18 properties. PPS/multiwall carbon nanotube composites ﬁbers have been found electrically conductive for EMS purposes. The SE of copper/cotton core-sheath yarns based on 2-dimensional (2D) fabrics was also satisfactory. Maximum researchers have selected 2D woven architecture and studied the effect of different parameters in the various frequency ranges. In the case of 2D woven archi- tecture, it is impossible to keep a thread straight. It is concluded that by bending the conductive yarns, the EMS potential decreases. Three-dimensional woven architecture is more challenging to construct than 2D conventional woven fabrics. In 2D woven architecture, only one layer of thread is used, but in 3D orthogonal architecture, the number of successive thread layers is not restricted. The 3D fabrics are conﬁgured along the X, Y, and Z-axis, imparting high strength in all three directions. The higher thickness of 3D fabrics offers more opportunities for fabric engineering and product development, especially for EMS purposes. Three-dimensional orthogonal fabric preforms were produced using E-glass ﬁber as a signiﬁcant component to enhance fabric thickness, impact resistance, and delamination resistance. Preforms are converted to composite and found to have the maximum in- ﬂuence of vertical yarn layers on impact resistance and Charpy impact energies. The yarn parameters have a higher impact on a load-elongation curve rather than ﬁber properties. Finite element deformation modeling considers jammed and non-jammed 3D orthogonal structure geometry with tensile properties of constituent yarns and resins with spun and ﬁlament yarns. The model has successfully predicted the results close to experimental ﬁndings. The interaction between electromagnetic energy and textile fabrics is essential for designing and realizing electromagnetic shielding/absorptive fabrics. Conceptually, when electromagnetic energy is incident on fabric, some part of the energy reﬂects, transmits, and absorbs. The share of reﬂection, remittance, and absorption depends on the fabric material’s thickness and conductivity. To engineer the textile structure of desired EMS, the electromagnetic conductivity of yarns and thickness of the textile structure play a vital role. The author’s best knowledge of the 3D orthogonal fabrics, which have considerably higher thickness than 2D fabrics with stuffer yarn presence, did not consider for elec- tromagnetic shielding purposes by other researchers. The unconventional structure of 3D fabrics has enough potential to engineer better ES. The 3D orthogonal fabric samples are manufactured as per response surface meth- odology (RMS) and Box–Behnken design of experiment by altering the copper ﬁlament diameter, the linear density of PPS ﬁber, and hybrid yarns. Singh et al. 6669S The present work will provide a concrete platform to establish the mechanism and relationship between various parameters of the 3D orthogonal structure in which warp threads are nonconductive yarns, and weft threads are copper ﬁlament-based core-sheath hybrid yarn. Material and method A three-level, and three factor Box–Behnken design of experiment was employed for maximizing EMS of 3D orthogonal fabrics by changing copper ﬁlament diameter, PPS yarn diameter, and hybrid yarn tex at three levels by shells based on 15 different fabric samples as opted by some other researchers for optimization purposes. To optimize the inﬂuence of PPS ﬁber diameter, copper ﬁlament diameter, and hybrid yarn linear density on EM shielding of orthogonal fabrics, Box and Behnken response surface design of experiment was employed in this study as given in Table 1 and Table 2. Many researchers have agreed that sample manufacturing with each possible factorial combination of the specimen variables is unrealistic because of the sizeable number of samples needed. Hence, the Box–Behnken design of experiment, a response surface modeling, has been adopted for analyzing the inﬂuence of various variables affecting the response by altering them simultaneously and conducting a restricted number of ex- periments. Box–Behnken design has been popularly used for the second-order response surface model with a minimum number of trials, which is not possible in traditional factorial designs. It is created by merging two-level factorial designs with partial block designs in an exceptional approach. The sample manufacturing for each block is replaced 27–30 by an identical design. Conductive hybrid yarns of linear density 300, 350, and 400 tex are manufactured using PPS at sheath and copper monoﬁlament of 0.05, 0.1, and 0.15 mm diameter at the core as a similar range of copper ﬁlament diameter has opted for conventional knitted fabrics for EMS purposes. Different core-sheath copper/PPS hybrid yarns are produced on a Fehrer AG type DREF-III friction spinning machine. The core is ﬁlled by feeding the copper monoﬁlament of 0.05, 0.10, and 0.15 mm diameter and four PPS slivers for sheath ﬁbers. The feed rate and draft of drafting units are adjusted so that the total yarn tex must meet the desired linear density. The spinning-drum speed and the yarn delivery speed were kept constant at 2500 rpm and 50 m/min, respectively, for all the samples. The cross- sectional view of the 3D orthogonal fabric and the conductive hybrid yarn is given in Figure 1. The fabrication of 3D orthogonal fabric was carried out by making special arrangements in the CCITech sample loom employing additional beams. Various Table 1. Optimized parameters for design of 3D orthogonal fabric. Variables Labels Level 1 (1) Level 2 0) Level 3 (+1) PPS ﬁber diameter (μ)P1 10 15 20 Conductive copper ﬁlament diameter in (mm) P2 0.05 0.10 0.15 Hybrid yarn linear density (tex) P3 300 350 400 6670S Journal of Industrial Textiles 51(4S) Table 2. Scheme of Box and Behnken design of experiment. Run (P1) (P2) (P3) 1 10 0.05 350 2 20 0.05 350 3 10 0.15 350 4 20 0.15 350 5 10 0.10 300 6 20 0.10 300 7 10 0.10 400 8 20 0.10 400 9 15 0.05 300 10 15 0.15 300 11 15 0.05 400 12 15 0.15 400 13 15 0.10 350 14 15 0.10 350 15 15 0.10 350 Figure 1. Cross-sectional and surface view of 3D orthogonal fabric. Singh et al. 6671S parameters such as axial yarn movement, binder yarn (Y), weft yarns are optimized for various experimental works. The exemplary architecture of 3D orthogonal fabric is given in Figure 2. The thickness of 3D orthogonal fabrics is kept constant by engineering the internal yarn free space, as shown in Figure 2. Electromagnetic shielding test under free space measurement system The fabric samples are characterized for electromagnetic shielding and shielding ef- fectiveness in the K-under ðK Þ band. The K band is the section of the electromagnetic U U spectrum in the microwave scale of frequencies from 12 to 18 GHz which is used in radar applications. The electromagnetic studies of the developed prototype fabrics were carried out using the free-space measurement system. The basic methodology of this system is based on the measurement of reﬂectance and transmittance of material under test (Figure 3). The transmitting electromagnetic waves and receiving antenna are supplemented by a couple of focusing horn lenses in the measurement system. A pair of identical plano- convex dielectric lenses is arranged back-to-back in a conical horn antenna for spot focusing purposes. The ratio fraction between focal distance and lens diameter is kept one. Figure 2. Three-dimensional orthogonal fabric. 6672S Journal of Industrial Textiles 51(4S) Figure 3. Free space measurement system. The diameter D is approximately 30.5 cm, focal depth 10, and 3-dB beamwidth of antenna is kept for antenna which is used for having a wavelength of measurement frequency. The electromagnetic shielding potential of material from fall electromagnetic energy is represented by electromagnetic shielding efﬁciency (SE). The incident energy that falls on the shielding specimen is divided in reﬂection, absorption, and transmission. Therefore, the shielding effectiveness is the summation of reﬂection, absorption, multiple internal reﬂections, and transmission, which provides total enfeeblement as concluded by a researcher P E H I I I SE ¼ 10 log ¼ 20 log ¼ 20 log ¼ SR þ SE þ SE (1) T R A M P E H T T T where P, E, H refer to power, electric, and magnetic ﬁeld intensities while subscripts I, R, and T represent the incident, reﬂected, and transmitted components, respectively, as shown in Figure 4. The SE refers to net reﬂection, and SE represents net absorption. R A The interaction pattern of incident reﬂected and transmitted electromagnetic wave incident on a 3D material is represented in Figure 4 as described earlier also. Electromagnetic shielding by fabrics The EMS of the ideal metal sample can be divided into absorption, reﬂection, and multiple reﬂections and is deﬁned as Singh et al. 6673S Figure 4. Interaction of electromagnetic waves with the material. EMS ¼ A þ BðdBÞþ R (2) where A is the absorption of electromagnetic waves, B is the loss in electromagnetic waves intensity due to multiple reﬂections, and R is the reﬂection loss. In the case of plain- woven fabric surface, the EMS is calculated by pﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ μ f SE ¼ 168:16 10 log þ 1:31 þ f μ σ ðdBÞ (3) where μ is the relative magnetic permeability, σ is the relative conductivity, and f is the r r frequency (H ). The equation of EMS can be wriiten as EMS ¼ 20 log where μ is the frequency amplitude without shielding and μ is the amplitude at same 0 s frequency point with a shield. The 3D orthogonal fabrics have higher thickness and uneven surface proﬁles that did not have an effective model to predict EMS orthogonal fabrics. Results and discussion As per Box and Behnken’s experiment design, 15 samples were prepared and tested for reﬂectance and EMS. Analysis of variance (ANOVA) of EMS test results has been done to investigate the effects of the three factors on the EMS of the samples. The ANOVA inferences are shown in Table 3 in coded units. The F-value of the model is 37.20 with a p-value of 0.0265 that denotes the model is signiﬁcant, and the chances of noise in this model are only 2.65%, as shown in Table 3. The p-value of a model is less than 0.0500, which indicates that the model terms are 2 2 2 2 signiﬁcant at a 95% conﬁdence level. In this case, A, B, C, AC, A ,C ,A B, and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence interval is with PPS yarn diameter where p-value is 0.0077, having a signiﬁcantimpactonEMS. At low copper ﬁlament diameter, the PPS yarn diameter increases from 10 to 20 μm, and the EMS value increases gradually. However, at a high level of copper ﬁlament 6674S Journal of Industrial Textiles 51(4S) Table 3. Analysis of variance (ANOVA) of electromagnetic shielding test results at frequency 13.0 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 380.96 12 31.75 37.20 0.0265 Signiﬁcant A-PPS yarn dia 109.73 1 109.73 128.58 0.0077 Signiﬁcant B-copper ﬁlament 22.71 1 22.71 26.61 0.0356 diameter C-hybrid yarn linear 60.92 1 60.92 71.39 0.0137 Signiﬁcant density AB 1.38 1 1.38 1.62 0.3313 AC 54.10 1 54.10 63.39 0.0154 Signiﬁcant BC 14.78 1 14.78 17.33 0.0532 A 40.16 1 40.16 47.06 0.0206 Signiﬁcant B 2.14 1 2.14 2.51 0.2538 C 32.29 1 32.29 37.84 0.0254 Signiﬁcant A B 37.32 1 37.32 43.74 0.0221 Signiﬁcant A C 4.99 1 4.99 5.85 0.1367 AB 54.08 1 54.08 63.38 0.0154 Signiﬁcant Pure error 1.71 2 0.8533 Cor total 382.67 14 Figure 5. Effect of copper ﬁlament diameter and PPS yarn diameter on EMS at frequency 13.0 GHz. diameter, as PPS yarn diameter increases, EMS initially decreases than increases, as shown in Figure 5 that may be attributed to the conductive nature of the copper ﬁl- ament. A factual model is contoured in a coding unit of the factors to predict the EMS of the samples. The given model indicates a coefﬁcient of determination (R2) equal to Singh et al. 6675S 0.9955, implying excellent goodness of ﬁt. The model to predict EMS of hybrid orthogonal fabrics at 13 GHz is shown in equation (4) EMS ¼ 27:95 þ 5:24A 2:38B þ 3:90C 0:59AB 3:68AC þ 1:92BC þ 3:30A (4) 2 2 2 2 2 0:762B 2:96C þ 4:32A B 1:58A C 5:20AB The effect of copper ﬁlament diameter and PPS yarn diameter is shown in Figure 5(b). The EMS of orthogonal fabrics was found to be 18.2 dB at 10-micron yarn diameter, which increased to 23.8 dB almost linearly at 20 micron yarn diameter at 13.0 GHz frequency (Figure 5(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁl- ament diameter and was found to be 18.2 dB at 0.05 mm copper ﬁlament diameter, which further increased to 33 dB at 0.15 mm copper ﬁlament diameter at 13.0 GHz frequency was associated to resonance due to metal characteristics (Figure 5(C)). The effect of PPS yarn diameter and hybrid yarn tex is shown in Figure 6(b). The EMS of orthogonal fabrics was found to be 15 dB at 10-micron yarn diameter, which increased to 34 dB almost linearly at 20 micron yarn diameter at 13.0 GHz frequency (Figure 6(a)). The EMS of orthogonal fabrics was inﬂuenced by hybrid yarn tex and was found to be 15 dB at 300 tex hybrid yarn linear density, which further increased to 29 dB at 400 tex hybrid yarn linear density at 13.0 GHz frequency and was associated to resonance due to metal characteristics (Figure 6(C)). The orthogonal structure of the PPS molecular chains and copper conductive monoﬁlament network offers the selective distribution of electromagnetic (EM) waves. An effective shielding comes in the conductive interfacial connection between sulfur and silver combination. A much cheaper copper monoﬁlament replaces the silver ﬁller to keep the advantage of sulfur–copper interfacial interaction in EM shielding, illustrated in Figure 6. The conducting copper monoﬁlament decreases the amplitude of electro- magnetic waves exponentially, which is inﬂuenced by skin depth. This effect remains similar at 15.5 and 18 GHz also as shown in Tables 4 and 5. A similar trend was observed in silver-plated ﬁlament yarns. The effect of copper ﬁlament diameter and hybrid yarn linear density (tex) is shown in Figure 7(b). The EMS of orthogonal fabrics was found to be 15 dB at 300 tex hybrid yarn Figure 6. Effect of hybrid yarn count (tex) and PPS yarn diameter on EMS at frequency 13.0 GHz. 6676S Journal of Industrial Textiles 51(4S) Table 4. Electromagnetic shielding results at frequency 15.5 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 677.41 12 56.45 50.17 0.0197 Signiﬁcant A-PPS yarn dia 27.72 1 27.72 24.64 0.0383 Signiﬁcant B-copper ﬁlament 6.16 1 6.16 5.47 0.1442 dia C-hybrid yarn 37.23 1 37.23 33.08 0.0289 Signiﬁcant count AB 0.8649 1 0.8649 0.7686 0.4731 AC 0.5256 1 0.5256 0.4671 0.5649 BC 114.95 1 114.95 102.16 0.0096 Signiﬁcant 59.72 1 59.72 53.07 0.0183 Signiﬁcant B 72.79 1 72.79 64.69 0.0151 Signiﬁcant C 71.40 1 71.40 63.45 0.0154 Signiﬁcant A B 0.0005 1 0.0005 0.0004 0.9852 A C 10.87 1 10.87 9.66 0.0898 AB 36.68 1 36.68 32.60 0.0293 Signiﬁcant Pure error 2.25 2 1.13 Cor. Total 679.66 14 Table 5. ANOVA of electromagnetic shielding test results at frequency 18.0 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 366.78 12 30.57 31.83 0.0308 Signiﬁcant A-PPS yarn dia 102.82 1 102.82 107.09 0.0092 Signiﬁcant B-copper ﬁlament 22.71 1 22.71 23.65 0.0398 Signiﬁcant dia C-hybrid yarn 59.37 1 59.37 61.83 0.0158 Signiﬁcant count AB 1.63 1 1.63 1.69 0.3229 AC 53.14 1 53.14 55.35 0.0176 Signiﬁcant BC 14.03 1 14.03 14.61 0.0621 A 39.58 1 39.58 41.23 0.0234 Signiﬁcant B 1.91 1 1.91 1.98 0.2943 C 30.64 1 30.64 31.92 0.0299 Signiﬁcant A B 34.78 1 34.78 36.22 0.0265 Signiﬁcant A C 4.49 1 4.49 4.67 0.1632 AB 52.69 1 52.69 54.87 0.0177 Signiﬁcant Pure error 1.92 2 0.9601 Cor. Total 368.70 14 Singh et al. 6677S Figure 7. Effect of hybrid yarn count (tex) and copper ﬁlament diameter on EMS at frequency 13.0 GHz. linear density, which increased to 28 dB almost linearly at 400 tex linear density of hybrid yarn at 13.0 GHz frequency (Figure 7(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁlament diameter and was found to be 15 dB at 0.05 mm copper ﬁlament diameter, whichfurther increasedto24.5dBat0.15mmcopper ﬁlament diameter at 13.0 GHz frequency and was associated to resonance due to metal characteristics (Figure 7(c)). The EM shielding increases due to the increase in skin effect and decrease in electro- magnetic wave amplitude, as similarly concluded in steel/polypropylene hybrid yarns. A linear relationship between the PPS yarn diameter and EMS was observed. The EMS of orthogonal fabric samples was increased with an increase in hybrid yarn linear density at 13.0 GHz, as shown in Figure 7(a) and Figure 7(c). An increasing yarn linear density produces a tightly woven fabric that gives an improved EMS effect, which can be observed from Figure 7(b), and similar trends were found in the interlock knitted fabrics to establish the relationship between shielding and tightness of EMS fabrics. The EMS increases with increasing hybrid yarn linear density attribute to the effect of PPS ﬁbers in increasing EMS of fabric samples. The PPS has low melt viscosity, which assists in diffusing electromagnetic waves between conductive ﬁllers and the molecular chains of PPS itself. Conductive copper ﬁlaments have played the role of conductive ﬁllers in these orthogonal fabrics. The F-value 50.17 and p-value 0.0197 denote that the model is signiﬁcant, and the chance of noise in this model is 1.97%, as shown in Table 4. p-values less than 0.05 indicate that model terms are signiﬁcant at a 95% conﬁdence level. In this case, A, C, BC, 2 2 2 2 A ,B ,C , and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence level is with copper ﬁlament diameter along with hybrid yarn linear density, where the p-value is 0.0096 having a signiﬁcant impact on EMS as shown in Figure 8 as is similarly concluded the effect of conductive yarn density on EMS in 2D fabric. An empirical model is ﬁtted in a coding unit of the factors to predict the EMS of the samples. The model shows a coefﬁcient of determination (R2) equal to 0.9967, which implies goodness of ﬁt. The model is shown in equation (5). 6678S Journal of Industrial Textiles 51(4S) Figure 8. Effect of copper ﬁlament diameter and PPS yarn diameter on EMS at frequency 15.5 GHz. Adequate precision is used to measure the signal-to-noise ratio. A ratio greater than 4 is desirable for a practical EM shielding fabric. The current ratio is 18.723, which indicates an adequate signal. This model can be used to navigate the design space. The model to predict EMS of hybrid orthogonal fabrics at 15.5 GHz is shown in equation (5) EMS ¼ 47:11 þ 2:63A 1:24B þ 3:05C þ 0:46AB 0:3625AC þ 5:36BC 4:02A 2 2 2 2 2 4:44B 4:4C þ 0:0157A B þ 2:33A C þ 4:28B (5) The effect of copper ﬁlament diameter and PPS yarn diameter is shown in Figure 8(b). The EMS of orthogonal fabrics was found to be 18 dB at 10-micron PPS yarn diameter, which increased to 36 dB almost linearly at 20 micron PPS yarn diameter at 15.5 GHz (Figure 8(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁlament diameter and was found to be 18 dB at 0.05 mm copper ﬁlament diameter, which further increased to 27 at dB at 0.11 mm copper ﬁlament diameter (Figure 8(c)). The conductive hybrid yarn diameter mainly increases by an increase in the diameter of the core copper ﬁlament. It is noticed from Figure 9 that the EMS effect is increased from 18 to 32 dB by accounting an increase in hybrid yarn linear density from 300 to 400 tex. The EMS was found 18 dB at 10-micron yarn diameter, which then increased to 28 dB at 16-micron yarn diameter at 15.5 GHz frequency (Figure 9(a)). The EM shielding was inﬂuenced by hybrid yarn linear density (tex) at 15.5 GHz frequency. The EM shielding was found to be 18 dB at 300 tex, which increased to 32 dB at 380 tex (Figure 9(a)). It is observed in Figure 10 that by an increase in hybrid yarn linear density, the EMS rises. The EM shielding was 15 dB in the presence of 300 tex hybrid yarn, which increases to 36 dB with 400 tex hybrid yarns at 15.5 GHz frequency (Figure 10(a)), and that may be attributed to increasing reﬂection, absorption, and internal reﬂection by increasing yarn diameters as similarly observed in 2D hybrid fabrics. The copper ﬁlament diameter also Singh et al. 6679S Figure 9. Effect of hybrid yarn tex and PPS yarn diameter on EMS at frequency 15.5 GHz. Figure 10. Effect of copper ﬁlament diameter and hybrid yarn tex on EMS at frequency 15.5 GHz. Figure 11. Effect of hybrid yarn count (tex) and copper ﬁlament diameter on EMS at 18 GHz. 6680S Journal of Industrial Textiles 51(4S) Table 6. Test results of reﬂectance and EMS. Response Factor 1 Factor 2 Factor 3 Response1 Response 2 Response 3 4 Hybrid yarn PPS yarn diameter (A) Copper ﬁlament diameter Tex (C) Reﬂectance Transmittance Absorbance Std Run (micrometer) (B) (mm) (Tex) (%) (%) (%) EMS (dB) 3 1 10 0.15 350 28.9 85.01 9.08 32.97 2 2 20 0.05 350 28.76 85.16 9.83 29.17 15 3 15 0.10 350 31.42 85.20 10.79 28.48 13 4 15 0.10 350 31.03 83.97 11.03 28.48 8 5 20 0.10 400 26.24 82.83 12.17 32.17 4 6 20 0.15 350 27.97 83.54 10.16 31.87 6 7 20 0.10 300 21.03 63.03 06.03 34.88 11 8 15 0.05 400 22.06 64.04 07.04 28.59 5 9 10 0.10 300 27.58 84.84 10.16 17.05 1 10 10 0.05 350 28.02 83.13 09.87 27.92 10 11 15 0.15 300 29.26 84.30 10.69 16.02 12 12 15 0.15 400 28.49 77.94 17.06 27.67 9 13 15 0.05 300 29.86 84.59 10.01 24.63 14 14 15 0.10 350 30.17 85.21 09.79 26.88 7 15 10 0.10 400 29.37 75.47 16.59 29.05 Singh et al. 6681S inﬂuenced the EMS of orthogonal fabrics. The EMS of the fabric sample was found to be 16 dB in the presence of 0.05 mm diameter copper ﬁlament, which reaches 32 dB as copper ﬁlament diameter increases to 0.15 mm at 15.5 GHz frequency (Figure 10(c)). The EM shielding of orthogonal fabrics was increased by increasing copper ﬁlament diameter and hybrid yarn linear density at 18.0 GHz frequency (Figure 11(b)). The value of EMS was found to be 30.4 dB at a copper ﬁlament diameter of 0.05 mm, which increased to 39.6 dB at a copper ﬁlament diameter of 0.15 mm at 18.0 GHz frequency (Figure 11 (a)). The EM shielding was found to be 30.4 dB at hybrid yarn linear density of 300 tex, which was increased to 43.2 dB at 400 yarn tex at 18.0 GHz frequency (Figure 11 (c)). The F-value 31.83 and p-value 0.0308 denote that the model is signiﬁcant, and the chance of noise in this model is 1.92%. p-values less than 0.0500 indicate that model 2 2 2 terms are signiﬁcant at a 95% conﬁdence level. In this case, A, B, C, AC, A ,C ,A B, and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence level is with PPS yarn diameter where the p-value is 0.0092 having a signiﬁcant impact on EMS as shown in Figure 11. An empirical model is ﬁtted in a coding unit of the factors to predict the EMS of the samples. The model shows a coefﬁcient of determination (R2) equal to 0.9948, which implies goodness of ﬁt. The model to predict EMS of hybrid orthogonal fabrics at 18 GHz is shown in equation (6) EMS ¼ 43:12 þ 5:07A 2:38B þ 3:85C 0:638AB 3:65AC þ 1:87BC þ 3:27A 2 2 2 2 2 0:7183B 2:88C þ 4:17A B 1:50A C 5:13AB (6) It has been observed from Table 6 that when the copper yarns are parallel to the orientation of the incident electric ﬁeld, there is a maximum of 85.21% transmission of incident energy, and thereby minimum effective electromagnetic shielding of 26.88 dB is achieved. Further, the studies show that under this conﬁguration of customized fabric, minimum reﬂectance of 21.03% has been achieved, and the reﬂectance values show an increasing trend across the intended frequency region. Conclusion Three-dimensional orthogonal structures of multifunctional metal composite fabrics have been developed. The EM shielding of 3D orthogonal fabrics is greatly inﬂuenced by hybrid yarn linear density, copper ﬁlament diameter, and PPS yarn diameter in the Ku band (12–18 GHz) of electromagnetic waves. � The incident electromagnetic energy can be managed by altering the diameter and the orientation of copper monoﬁlament-based hybrid yarns in a 3D orthogonal structure. The alignment of copper yarns perpendicular to the direction of the incident electric ﬁeld shows minimum (0.97–1.15%) transmission of incident 6682S Journal of Industrial Textiles 51(4S) energy, and, correspondingly, effective electromagnetic shielding of 15% is achieved across the frequency region. � Making changes in copper ﬁlament diameter, hybrid yarn linear density, and PPS ﬁber linear density in 3D orthogonal fabric offers reﬂectance of 21%, giving an increasing trend of EMS across the intended frequency region. � The results are statistically tested by two-way ANOVA and was found that the proposed model is suitable to assist further improvement in 3D fabrics engineering for EMS applications. � The future scope of this work will enable the manufacturing of 3D orthogonal composite electromagnetic shields that can be used for enclosing military weapons, ﬁghting jets, and troops to be detected from radars. 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 iD Mukesh Kumar Singh https://orcid.org/0000-0002-3432-2038 References 1. Liu Z and Wang XC. Inﬂuence of fabric weave type on the effectiveness of electromagnetic shielding woven fabric. J Electromagn Waves Appl 2012; 26 (14): 1848–1856. 2. Shyr TW and Shie JW, Electromagnetic shielding mechanisms using soft magnetic stainless steel ﬁber enabled polyester textiles. J Magnet Magn Mat 2012; 324(23): 4127–4132. 3. Kamiya R, Cheeseman BA, Popper P and Chou TW. Some recent advances in the fabrication and design of three-dimensional textile preforms: a review. Comps Sci Tech 2000; 60(1): 33–47. 4. Go Q, Zhang Y, Ming R and Chen L. 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Singh et al. 6685S Appendix List of Abbreviation 3D Three-dimensional 2D Two-dimensional DREF Double drum based friction spinning system developed by Dr. ESF Electromagnetic shielding fabric EM Electromagnetic EMS Electromagnetic shielding EMSE Electromagnetic shielding effectiveness FSMS Free space measurement system GHz Gigahertz PPS Polyphenylene sulphide μ Relative magnetic permeability σ Relative conductivity f Frequency (H ) μ Frequency at amplitude without shielding μ Amplitude at same frequency point with a shield SE Shielding effectiveness due to reﬂection SE Shielding effectiveness due to absorption SE Shielding effectiveness http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Journal of Industrial Textiles SAGE http://www.deepdyve.com/lp/sage/optimization-of-electromagnetic-shielding-of-three-dimensional-bChIuFQrnA

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Publisher: SAGE
Copyright: © The Author(s) 2022
ISSN: 1528-0837
eISSN: 1530-8057
DOI: 10.1177/15280837211062054
Publisher site: See Article on Publisher Site

Abstract

Electromagnetic shielding (EMS) has become the necessity of the present era due to enormous expansion in electronic devices accountable to emit electromagnetic radiation. The principal target of this paper is to originate three-dimensional (3D) orthogonal fabrics with conductive hybrid weft yarn and to determine their electromagnetic shielding. DREF-III core-spun yarn using copper ﬁlament in the core and polyphenylene sulﬁde (PPS) ﬁber on the sheath and fabric constructed of such yarn has a promising elec- tromagnetic shielding characteristic. Box–Behnken experimental design has been em- ployed to prepare various samples to investigate the electromagnetic shielding efﬁciency of 3D orthogonal woven structures. The orthogonal fabric samples were tested in an electromagnetic Ku frequency band using free space measurement system (FSMS) to estimate absorbance, reﬂectance, transmittance, and electromagnetic shielding. The increase in copper core ﬁlament diameter and hybrid yarn linear density enhances the EMS of orthogonal fabric. Statistical analysis has been done to bring out the effect and interaction of various yarn and fabric variables on EMS. Metal ﬁlament diameter, ori- entation, sheath ﬁbers percentage, and fabric constructional parameters signiﬁcantly affected electromagnetic shielding efﬁciency. The inferences of this study can be applied in Uttar Pradesh Textile Technology Institute, Souterganj Kanpur, India Department of Textile and Fibre Engineering, IIT Delhi, New Delhi, India DMSRDE, GT Road Kanpur, India Corresponding author: Mukesh Kumar Singh, Uttar Pradesh Textile Technology Institute, 11/208 Souterganj, Parwati Bagla Road, Kanpur 208001, India. Email: mukesh70ster@gmail.com Singh et al. 6667S other 3D structures like angle interlock, spacer fabrics for curtains, and coverings for civilians and military applications. Keywords Conductive yarns, electromagnetic shielding, orthogonal structure, polyphenylene sulﬁde, reﬂectance, transmittance Introduction The EMS is required to shield electrical and electronic assemblies from external elec- tromagnetic (EM) ﬁelds. The electromagnetic shielding fabric (ESF) has inherent and soft functionalities which have found comprehensive application in civilian, industrial, and army-related electromagnetic shielding. The effect of yarn type, weave type, and fabric thickness on EMS was studied a little on two-dimensional fabrics. The fabric weave, an interlacement pattern of warp and weft thread containing conductive materials, is a crucial factor in inﬂuencing the shielding effectiveness (SE) of ESF in two-dimensional fabrics. 2–4 The plain weave fabric was found better than the twill weave fabric for EMS. The thread density and number of apertures do not effectively regulate the SE of metallic yarn- containing fabrics. The coarser yarns are found more effective in SE of EMS fabrics. With an enhancement in warp and weft density with the number of conductive fabric layers, an increase in EMS is witnessed in 3/1 twill copper fabrics. Copper is found more effective than brass in EMS fabric manufacturing. An effective physical model was developed to predict the SE of EMS fabrics by considering lateral longitudinal yarn, conductive ﬁbers, and yarn diameter as input 7 8 parameters. The metal ﬁber content per unit area has enhanced SE in EMS fabrics. The effect of the copper content in copper/glass knitted polypropylene composite, linear yarn density, and stitch density is studied for electromagnetic shielding and shielding effectiveness. Metal and polyester ﬁlaments are used to produce a metallic grid in conductive fabrics. The study concludes that electromagnetic shielding effectiveness (EMSE) increases with metal content and the square grid structure. The cotton/copper hybrid yarns possess higher EMSE than cotton/stainless steel hybrid yarns fabric without a signiﬁcant effect of weave. Silver coated cotton yarn and silver core-sheath ring yarns produce single jersey knitted fabric for electromagnetic shielding. The fabric produced by the plating technique shows higher EMS than core-spun yarn knitted fabrics at low-frequency regions. A mathematical model also found a high degree of correlation between predicted and measured EMS values in metallic hybrid yarn-based 2D fabrics when metal yarn di- ameter, metallic yarn periodic spacing, electric conductivity, electromagnetic wave polarization direction, and the weaving angle were considered as input parameters. The plain-woven 2D fabric samples manufactured by core-sheath stainless steel/polyester yarn were exhibited that the direction of hybrid yarns and warp-weft yarn densities affects the SE of EMS fabrics. 6668S Journal of Industrial Textiles 51(4S) Polyphenylene sulﬁde (PPS) ﬁber/copper particles composites have been successfully utilized to manufacture electrical conductive fabric. However, PPS did not cover copper wire as sheath material for EMS purposes although copper wires were used to develop 15,16 textile-based sensors and actuators. PPS staple ﬁber, a semi-crystalline thermoplastic material selected to cover the copper monoﬁlament using the DREF-III spinning process, has found versatile applications due to its outstanding electrical, tensile, and thermal applications, and inherent ﬂame retardant 17,18 properties. PPS/multiwall carbon nanotube composites ﬁbers have been found electrically conductive for EMS purposes. The SE of copper/cotton core-sheath yarns based on 2-dimensional (2D) fabrics was also satisfactory. Maximum researchers have selected 2D woven architecture and studied the effect of different parameters in the various frequency ranges. In the case of 2D woven archi- tecture, it is impossible to keep a thread straight. It is concluded that by bending the conductive yarns, the EMS potential decreases. Three-dimensional woven architecture is more challenging to construct than 2D conventional woven fabrics. In 2D woven architecture, only one layer of thread is used, but in 3D orthogonal architecture, the number of successive thread layers is not restricted. The 3D fabrics are conﬁgured along the X, Y, and Z-axis, imparting high strength in all three directions. The higher thickness of 3D fabrics offers more opportunities for fabric engineering and product development, especially for EMS purposes. Three-dimensional orthogonal fabric preforms were produced using E-glass ﬁber as a signiﬁcant component to enhance fabric thickness, impact resistance, and delamination resistance. Preforms are converted to composite and found to have the maximum in- ﬂuence of vertical yarn layers on impact resistance and Charpy impact energies. The yarn parameters have a higher impact on a load-elongation curve rather than ﬁber properties. Finite element deformation modeling considers jammed and non-jammed 3D orthogonal structure geometry with tensile properties of constituent yarns and resins with spun and ﬁlament yarns. The model has successfully predicted the results close to experimental ﬁndings. The interaction between electromagnetic energy and textile fabrics is essential for designing and realizing electromagnetic shielding/absorptive fabrics. Conceptually, when electromagnetic energy is incident on fabric, some part of the energy reﬂects, transmits, and absorbs. The share of reﬂection, remittance, and absorption depends on the fabric material’s thickness and conductivity. To engineer the textile structure of desired EMS, the electromagnetic conductivity of yarns and thickness of the textile structure play a vital role. The author’s best knowledge of the 3D orthogonal fabrics, which have considerably higher thickness than 2D fabrics with stuffer yarn presence, did not consider for elec- tromagnetic shielding purposes by other researchers. The unconventional structure of 3D fabrics has enough potential to engineer better ES. The 3D orthogonal fabric samples are manufactured as per response surface meth- odology (RMS) and Box–Behnken design of experiment by altering the copper ﬁlament diameter, the linear density of PPS ﬁber, and hybrid yarns. Singh et al. 6669S The present work will provide a concrete platform to establish the mechanism and relationship between various parameters of the 3D orthogonal structure in which warp threads are nonconductive yarns, and weft threads are copper ﬁlament-based core-sheath hybrid yarn. Material and method A three-level, and three factor Box–Behnken design of experiment was employed for maximizing EMS of 3D orthogonal fabrics by changing copper ﬁlament diameter, PPS yarn diameter, and hybrid yarn tex at three levels by shells based on 15 different fabric samples as opted by some other researchers for optimization purposes. To optimize the inﬂuence of PPS ﬁber diameter, copper ﬁlament diameter, and hybrid yarn linear density on EM shielding of orthogonal fabrics, Box and Behnken response surface design of experiment was employed in this study as given in Table 1 and Table 2. Many researchers have agreed that sample manufacturing with each possible factorial combination of the specimen variables is unrealistic because of the sizeable number of samples needed. Hence, the Box–Behnken design of experiment, a response surface modeling, has been adopted for analyzing the inﬂuence of various variables affecting the response by altering them simultaneously and conducting a restricted number of ex- periments. Box–Behnken design has been popularly used for the second-order response surface model with a minimum number of trials, which is not possible in traditional factorial designs. It is created by merging two-level factorial designs with partial block designs in an exceptional approach. The sample manufacturing for each block is replaced 27–30 by an identical design. Conductive hybrid yarns of linear density 300, 350, and 400 tex are manufactured using PPS at sheath and copper monoﬁlament of 0.05, 0.1, and 0.15 mm diameter at the core as a similar range of copper ﬁlament diameter has opted for conventional knitted fabrics for EMS purposes. Different core-sheath copper/PPS hybrid yarns are produced on a Fehrer AG type DREF-III friction spinning machine. The core is ﬁlled by feeding the copper monoﬁlament of 0.05, 0.10, and 0.15 mm diameter and four PPS slivers for sheath ﬁbers. The feed rate and draft of drafting units are adjusted so that the total yarn tex must meet the desired linear density. The spinning-drum speed and the yarn delivery speed were kept constant at 2500 rpm and 50 m/min, respectively, for all the samples. The cross- sectional view of the 3D orthogonal fabric and the conductive hybrid yarn is given in Figure 1. The fabrication of 3D orthogonal fabric was carried out by making special arrangements in the CCITech sample loom employing additional beams. Various Table 1. Optimized parameters for design of 3D orthogonal fabric. Variables Labels Level 1 (1) Level 2 0) Level 3 (+1) PPS ﬁber diameter (μ)P1 10 15 20 Conductive copper ﬁlament diameter in (mm) P2 0.05 0.10 0.15 Hybrid yarn linear density (tex) P3 300 350 400 6670S Journal of Industrial Textiles 51(4S) Table 2. Scheme of Box and Behnken design of experiment. Run (P1) (P2) (P3) 1 10 0.05 350 2 20 0.05 350 3 10 0.15 350 4 20 0.15 350 5 10 0.10 300 6 20 0.10 300 7 10 0.10 400 8 20 0.10 400 9 15 0.05 300 10 15 0.15 300 11 15 0.05 400 12 15 0.15 400 13 15 0.10 350 14 15 0.10 350 15 15 0.10 350 Figure 1. Cross-sectional and surface view of 3D orthogonal fabric. Singh et al. 6671S parameters such as axial yarn movement, binder yarn (Y), weft yarns are optimized for various experimental works. The exemplary architecture of 3D orthogonal fabric is given in Figure 2. The thickness of 3D orthogonal fabrics is kept constant by engineering the internal yarn free space, as shown in Figure 2. Electromagnetic shielding test under free space measurement system The fabric samples are characterized for electromagnetic shielding and shielding ef- fectiveness in the K-under ðK Þ band. The K band is the section of the electromagnetic U U spectrum in the microwave scale of frequencies from 12 to 18 GHz which is used in radar applications. The electromagnetic studies of the developed prototype fabrics were carried out using the free-space measurement system. The basic methodology of this system is based on the measurement of reﬂectance and transmittance of material under test (Figure 3). The transmitting electromagnetic waves and receiving antenna are supplemented by a couple of focusing horn lenses in the measurement system. A pair of identical plano- convex dielectric lenses is arranged back-to-back in a conical horn antenna for spot focusing purposes. The ratio fraction between focal distance and lens diameter is kept one. Figure 2. Three-dimensional orthogonal fabric. 6672S Journal of Industrial Textiles 51(4S) Figure 3. Free space measurement system. The diameter D is approximately 30.5 cm, focal depth 10, and 3-dB beamwidth of antenna is kept for antenna which is used for having a wavelength of measurement frequency. The electromagnetic shielding potential of material from fall electromagnetic energy is represented by electromagnetic shielding efﬁciency (SE). The incident energy that falls on the shielding specimen is divided in reﬂection, absorption, and transmission. Therefore, the shielding effectiveness is the summation of reﬂection, absorption, multiple internal reﬂections, and transmission, which provides total enfeeblement as concluded by a researcher P E H I I I SE ¼ 10 log ¼ 20 log ¼ 20 log ¼ SR þ SE þ SE (1) T R A M P E H T T T where P, E, H refer to power, electric, and magnetic ﬁeld intensities while subscripts I, R, and T represent the incident, reﬂected, and transmitted components, respectively, as shown in Figure 4. The SE refers to net reﬂection, and SE represents net absorption. R A The interaction pattern of incident reﬂected and transmitted electromagnetic wave incident on a 3D material is represented in Figure 4 as described earlier also. Electromagnetic shielding by fabrics The EMS of the ideal metal sample can be divided into absorption, reﬂection, and multiple reﬂections and is deﬁned as Singh et al. 6673S Figure 4. Interaction of electromagnetic waves with the material. EMS ¼ A þ BðdBÞþ R (2) where A is the absorption of electromagnetic waves, B is the loss in electromagnetic waves intensity due to multiple reﬂections, and R is the reﬂection loss. In the case of plain- woven fabric surface, the EMS is calculated by pﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃﬃ μ f SE ¼ 168:16 10 log þ 1:31 þ f μ σ ðdBÞ (3) where μ is the relative magnetic permeability, σ is the relative conductivity, and f is the r r frequency (H ). The equation of EMS can be wriiten as EMS ¼ 20 log where μ is the frequency amplitude without shielding and μ is the amplitude at same 0 s frequency point with a shield. The 3D orthogonal fabrics have higher thickness and uneven surface proﬁles that did not have an effective model to predict EMS orthogonal fabrics. Results and discussion As per Box and Behnken’s experiment design, 15 samples were prepared and tested for reﬂectance and EMS. Analysis of variance (ANOVA) of EMS test results has been done to investigate the effects of the three factors on the EMS of the samples. The ANOVA inferences are shown in Table 3 in coded units. The F-value of the model is 37.20 with a p-value of 0.0265 that denotes the model is signiﬁcant, and the chances of noise in this model are only 2.65%, as shown in Table 3. The p-value of a model is less than 0.0500, which indicates that the model terms are 2 2 2 2 signiﬁcant at a 95% conﬁdence level. In this case, A, B, C, AC, A ,C ,A B, and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence interval is with PPS yarn diameter where p-value is 0.0077, having a signiﬁcantimpactonEMS. At low copper ﬁlament diameter, the PPS yarn diameter increases from 10 to 20 μm, and the EMS value increases gradually. However, at a high level of copper ﬁlament 6674S Journal of Industrial Textiles 51(4S) Table 3. Analysis of variance (ANOVA) of electromagnetic shielding test results at frequency 13.0 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 380.96 12 31.75 37.20 0.0265 Signiﬁcant A-PPS yarn dia 109.73 1 109.73 128.58 0.0077 Signiﬁcant B-copper ﬁlament 22.71 1 22.71 26.61 0.0356 diameter C-hybrid yarn linear 60.92 1 60.92 71.39 0.0137 Signiﬁcant density AB 1.38 1 1.38 1.62 0.3313 AC 54.10 1 54.10 63.39 0.0154 Signiﬁcant BC 14.78 1 14.78 17.33 0.0532 A 40.16 1 40.16 47.06 0.0206 Signiﬁcant B 2.14 1 2.14 2.51 0.2538 C 32.29 1 32.29 37.84 0.0254 Signiﬁcant A B 37.32 1 37.32 43.74 0.0221 Signiﬁcant A C 4.99 1 4.99 5.85 0.1367 AB 54.08 1 54.08 63.38 0.0154 Signiﬁcant Pure error 1.71 2 0.8533 Cor total 382.67 14 Figure 5. Effect of copper ﬁlament diameter and PPS yarn diameter on EMS at frequency 13.0 GHz. diameter, as PPS yarn diameter increases, EMS initially decreases than increases, as shown in Figure 5 that may be attributed to the conductive nature of the copper ﬁl- ament. A factual model is contoured in a coding unit of the factors to predict the EMS of the samples. The given model indicates a coefﬁcient of determination (R2) equal to Singh et al. 6675S 0.9955, implying excellent goodness of ﬁt. The model to predict EMS of hybrid orthogonal fabrics at 13 GHz is shown in equation (4) EMS ¼ 27:95 þ 5:24A 2:38B þ 3:90C 0:59AB 3:68AC þ 1:92BC þ 3:30A (4) 2 2 2 2 2 0:762B 2:96C þ 4:32A B 1:58A C 5:20AB The effect of copper ﬁlament diameter and PPS yarn diameter is shown in Figure 5(b). The EMS of orthogonal fabrics was found to be 18.2 dB at 10-micron yarn diameter, which increased to 23.8 dB almost linearly at 20 micron yarn diameter at 13.0 GHz frequency (Figure 5(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁl- ament diameter and was found to be 18.2 dB at 0.05 mm copper ﬁlament diameter, which further increased to 33 dB at 0.15 mm copper ﬁlament diameter at 13.0 GHz frequency was associated to resonance due to metal characteristics (Figure 5(C)). The effect of PPS yarn diameter and hybrid yarn tex is shown in Figure 6(b). The EMS of orthogonal fabrics was found to be 15 dB at 10-micron yarn diameter, which increased to 34 dB almost linearly at 20 micron yarn diameter at 13.0 GHz frequency (Figure 6(a)). The EMS of orthogonal fabrics was inﬂuenced by hybrid yarn tex and was found to be 15 dB at 300 tex hybrid yarn linear density, which further increased to 29 dB at 400 tex hybrid yarn linear density at 13.0 GHz frequency and was associated to resonance due to metal characteristics (Figure 6(C)). The orthogonal structure of the PPS molecular chains and copper conductive monoﬁlament network offers the selective distribution of electromagnetic (EM) waves. An effective shielding comes in the conductive interfacial connection between sulfur and silver combination. A much cheaper copper monoﬁlament replaces the silver ﬁller to keep the advantage of sulfur–copper interfacial interaction in EM shielding, illustrated in Figure 6. The conducting copper monoﬁlament decreases the amplitude of electro- magnetic waves exponentially, which is inﬂuenced by skin depth. This effect remains similar at 15.5 and 18 GHz also as shown in Tables 4 and 5. A similar trend was observed in silver-plated ﬁlament yarns. The effect of copper ﬁlament diameter and hybrid yarn linear density (tex) is shown in Figure 7(b). The EMS of orthogonal fabrics was found to be 15 dB at 300 tex hybrid yarn Figure 6. Effect of hybrid yarn count (tex) and PPS yarn diameter on EMS at frequency 13.0 GHz. 6676S Journal of Industrial Textiles 51(4S) Table 4. Electromagnetic shielding results at frequency 15.5 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 677.41 12 56.45 50.17 0.0197 Signiﬁcant A-PPS yarn dia 27.72 1 27.72 24.64 0.0383 Signiﬁcant B-copper ﬁlament 6.16 1 6.16 5.47 0.1442 dia C-hybrid yarn 37.23 1 37.23 33.08 0.0289 Signiﬁcant count AB 0.8649 1 0.8649 0.7686 0.4731 AC 0.5256 1 0.5256 0.4671 0.5649 BC 114.95 1 114.95 102.16 0.0096 Signiﬁcant 59.72 1 59.72 53.07 0.0183 Signiﬁcant B 72.79 1 72.79 64.69 0.0151 Signiﬁcant C 71.40 1 71.40 63.45 0.0154 Signiﬁcant A B 0.0005 1 0.0005 0.0004 0.9852 A C 10.87 1 10.87 9.66 0.0898 AB 36.68 1 36.68 32.60 0.0293 Signiﬁcant Pure error 2.25 2 1.13 Cor. Total 679.66 14 Table 5. ANOVA of electromagnetic shielding test results at frequency 18.0 GHz. Sum of Degree of Mean Source squares freedom square F-value p-value Model 366.78 12 30.57 31.83 0.0308 Signiﬁcant A-PPS yarn dia 102.82 1 102.82 107.09 0.0092 Signiﬁcant B-copper ﬁlament 22.71 1 22.71 23.65 0.0398 Signiﬁcant dia C-hybrid yarn 59.37 1 59.37 61.83 0.0158 Signiﬁcant count AB 1.63 1 1.63 1.69 0.3229 AC 53.14 1 53.14 55.35 0.0176 Signiﬁcant BC 14.03 1 14.03 14.61 0.0621 A 39.58 1 39.58 41.23 0.0234 Signiﬁcant B 1.91 1 1.91 1.98 0.2943 C 30.64 1 30.64 31.92 0.0299 Signiﬁcant A B 34.78 1 34.78 36.22 0.0265 Signiﬁcant A C 4.49 1 4.49 4.67 0.1632 AB 52.69 1 52.69 54.87 0.0177 Signiﬁcant Pure error 1.92 2 0.9601 Cor. Total 368.70 14 Singh et al. 6677S Figure 7. Effect of hybrid yarn count (tex) and copper ﬁlament diameter on EMS at frequency 13.0 GHz. linear density, which increased to 28 dB almost linearly at 400 tex linear density of hybrid yarn at 13.0 GHz frequency (Figure 7(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁlament diameter and was found to be 15 dB at 0.05 mm copper ﬁlament diameter, whichfurther increasedto24.5dBat0.15mmcopper ﬁlament diameter at 13.0 GHz frequency and was associated to resonance due to metal characteristics (Figure 7(c)). The EM shielding increases due to the increase in skin effect and decrease in electro- magnetic wave amplitude, as similarly concluded in steel/polypropylene hybrid yarns. A linear relationship between the PPS yarn diameter and EMS was observed. The EMS of orthogonal fabric samples was increased with an increase in hybrid yarn linear density at 13.0 GHz, as shown in Figure 7(a) and Figure 7(c). An increasing yarn linear density produces a tightly woven fabric that gives an improved EMS effect, which can be observed from Figure 7(b), and similar trends were found in the interlock knitted fabrics to establish the relationship between shielding and tightness of EMS fabrics. The EMS increases with increasing hybrid yarn linear density attribute to the effect of PPS ﬁbers in increasing EMS of fabric samples. The PPS has low melt viscosity, which assists in diffusing electromagnetic waves between conductive ﬁllers and the molecular chains of PPS itself. Conductive copper ﬁlaments have played the role of conductive ﬁllers in these orthogonal fabrics. The F-value 50.17 and p-value 0.0197 denote that the model is signiﬁcant, and the chance of noise in this model is 1.97%, as shown in Table 4. p-values less than 0.05 indicate that model terms are signiﬁcant at a 95% conﬁdence level. In this case, A, C, BC, 2 2 2 2 A ,B ,C , and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence level is with copper ﬁlament diameter along with hybrid yarn linear density, where the p-value is 0.0096 having a signiﬁcant impact on EMS as shown in Figure 8 as is similarly concluded the effect of conductive yarn density on EMS in 2D fabric. An empirical model is ﬁtted in a coding unit of the factors to predict the EMS of the samples. The model shows a coefﬁcient of determination (R2) equal to 0.9967, which implies goodness of ﬁt. The model is shown in equation (5). 6678S Journal of Industrial Textiles 51(4S) Figure 8. Effect of copper ﬁlament diameter and PPS yarn diameter on EMS at frequency 15.5 GHz. Adequate precision is used to measure the signal-to-noise ratio. A ratio greater than 4 is desirable for a practical EM shielding fabric. The current ratio is 18.723, which indicates an adequate signal. This model can be used to navigate the design space. The model to predict EMS of hybrid orthogonal fabrics at 15.5 GHz is shown in equation (5) EMS ¼ 47:11 þ 2:63A 1:24B þ 3:05C þ 0:46AB 0:3625AC þ 5:36BC 4:02A 2 2 2 2 2 4:44B 4:4C þ 0:0157A B þ 2:33A C þ 4:28B (5) The effect of copper ﬁlament diameter and PPS yarn diameter is shown in Figure 8(b). The EMS of orthogonal fabrics was found to be 18 dB at 10-micron PPS yarn diameter, which increased to 36 dB almost linearly at 20 micron PPS yarn diameter at 15.5 GHz (Figure 8(a)). The EMS of orthogonal fabrics was inﬂuenced by copper ﬁlament diameter and was found to be 18 dB at 0.05 mm copper ﬁlament diameter, which further increased to 27 at dB at 0.11 mm copper ﬁlament diameter (Figure 8(c)). The conductive hybrid yarn diameter mainly increases by an increase in the diameter of the core copper ﬁlament. It is noticed from Figure 9 that the EMS effect is increased from 18 to 32 dB by accounting an increase in hybrid yarn linear density from 300 to 400 tex. The EMS was found 18 dB at 10-micron yarn diameter, which then increased to 28 dB at 16-micron yarn diameter at 15.5 GHz frequency (Figure 9(a)). The EM shielding was inﬂuenced by hybrid yarn linear density (tex) at 15.5 GHz frequency. The EM shielding was found to be 18 dB at 300 tex, which increased to 32 dB at 380 tex (Figure 9(a)). It is observed in Figure 10 that by an increase in hybrid yarn linear density, the EMS rises. The EM shielding was 15 dB in the presence of 300 tex hybrid yarn, which increases to 36 dB with 400 tex hybrid yarns at 15.5 GHz frequency (Figure 10(a)), and that may be attributed to increasing reﬂection, absorption, and internal reﬂection by increasing yarn diameters as similarly observed in 2D hybrid fabrics. The copper ﬁlament diameter also Singh et al. 6679S Figure 9. Effect of hybrid yarn tex and PPS yarn diameter on EMS at frequency 15.5 GHz. Figure 10. Effect of copper ﬁlament diameter and hybrid yarn tex on EMS at frequency 15.5 GHz. Figure 11. Effect of hybrid yarn count (tex) and copper ﬁlament diameter on EMS at 18 GHz. 6680S Journal of Industrial Textiles 51(4S) Table 6. Test results of reﬂectance and EMS. Response Factor 1 Factor 2 Factor 3 Response1 Response 2 Response 3 4 Hybrid yarn PPS yarn diameter (A) Copper ﬁlament diameter Tex (C) Reﬂectance Transmittance Absorbance Std Run (micrometer) (B) (mm) (Tex) (%) (%) (%) EMS (dB) 3 1 10 0.15 350 28.9 85.01 9.08 32.97 2 2 20 0.05 350 28.76 85.16 9.83 29.17 15 3 15 0.10 350 31.42 85.20 10.79 28.48 13 4 15 0.10 350 31.03 83.97 11.03 28.48 8 5 20 0.10 400 26.24 82.83 12.17 32.17 4 6 20 0.15 350 27.97 83.54 10.16 31.87 6 7 20 0.10 300 21.03 63.03 06.03 34.88 11 8 15 0.05 400 22.06 64.04 07.04 28.59 5 9 10 0.10 300 27.58 84.84 10.16 17.05 1 10 10 0.05 350 28.02 83.13 09.87 27.92 10 11 15 0.15 300 29.26 84.30 10.69 16.02 12 12 15 0.15 400 28.49 77.94 17.06 27.67 9 13 15 0.05 300 29.86 84.59 10.01 24.63 14 14 15 0.10 350 30.17 85.21 09.79 26.88 7 15 10 0.10 400 29.37 75.47 16.59 29.05 Singh et al. 6681S inﬂuenced the EMS of orthogonal fabrics. The EMS of the fabric sample was found to be 16 dB in the presence of 0.05 mm diameter copper ﬁlament, which reaches 32 dB as copper ﬁlament diameter increases to 0.15 mm at 15.5 GHz frequency (Figure 10(c)). The EM shielding of orthogonal fabrics was increased by increasing copper ﬁlament diameter and hybrid yarn linear density at 18.0 GHz frequency (Figure 11(b)). The value of EMS was found to be 30.4 dB at a copper ﬁlament diameter of 0.05 mm, which increased to 39.6 dB at a copper ﬁlament diameter of 0.15 mm at 18.0 GHz frequency (Figure 11 (a)). The EM shielding was found to be 30.4 dB at hybrid yarn linear density of 300 tex, which was increased to 43.2 dB at 400 yarn tex at 18.0 GHz frequency (Figure 11 (c)). The F-value 31.83 and p-value 0.0308 denote that the model is signiﬁcant, and the chance of noise in this model is 1.92%. p-values less than 0.0500 indicate that model 2 2 2 terms are signiﬁcant at a 95% conﬁdence level. In this case, A, B, C, AC, A ,C ,A B, and AB are signiﬁcant model terms, and the most signiﬁcant value at 99% conﬁdence level is with PPS yarn diameter where the p-value is 0.0092 having a signiﬁcant impact on EMS as shown in Figure 11. An empirical model is ﬁtted in a coding unit of the factors to predict the EMS of the samples. The model shows a coefﬁcient of determination (R2) equal to 0.9948, which implies goodness of ﬁt. The model to predict EMS of hybrid orthogonal fabrics at 18 GHz is shown in equation (6) EMS ¼ 43:12 þ 5:07A 2:38B þ 3:85C 0:638AB 3:65AC þ 1:87BC þ 3:27A 2 2 2 2 2 0:7183B 2:88C þ 4:17A B 1:50A C 5:13AB (6) It has been observed from Table 6 that when the copper yarns are parallel to the orientation of the incident electric ﬁeld, there is a maximum of 85.21% transmission of incident energy, and thereby minimum effective electromagnetic shielding of 26.88 dB is achieved. Further, the studies show that under this conﬁguration of customized fabric, minimum reﬂectance of 21.03% has been achieved, and the reﬂectance values show an increasing trend across the intended frequency region. Conclusion Three-dimensional orthogonal structures of multifunctional metal composite fabrics have been developed. The EM shielding of 3D orthogonal fabrics is greatly inﬂuenced by hybrid yarn linear density, copper ﬁlament diameter, and PPS yarn diameter in the Ku band (12–18 GHz) of electromagnetic waves. � The incident electromagnetic energy can be managed by altering the diameter and the orientation of copper monoﬁlament-based hybrid yarns in a 3D orthogonal structure. The alignment of copper yarns perpendicular to the direction of the incident electric ﬁeld shows minimum (0.97–1.15%) transmission of incident 6682S Journal of Industrial Textiles 51(4S) energy, and, correspondingly, effective electromagnetic shielding of 15% is achieved across the frequency region. � Making changes in copper ﬁlament diameter, hybrid yarn linear density, and PPS ﬁber linear density in 3D orthogonal fabric offers reﬂectance of 21%, giving an increasing trend of EMS across the intended frequency region. � The results are statistically tested by two-way ANOVA and was found that the proposed model is suitable to assist further improvement in 3D fabrics engineering for EMS applications. � The future scope of this work will enable the manufacturing of 3D orthogonal composite electromagnetic shields that can be used for enclosing military weapons, ﬁghting jets, and troops to be detected from radars. 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 iD Mukesh Kumar Singh https://orcid.org/0000-0002-3432-2038 References 1. Liu Z and Wang XC. Inﬂuence of fabric weave type on the effectiveness of electromagnetic shielding woven fabric. J Electromagn Waves Appl 2012; 26 (14): 1848–1856. 2. Shyr TW and Shie JW, Electromagnetic shielding mechanisms using soft magnetic stainless steel ﬁber enabled polyester textiles. J Magnet Magn Mat 2012; 324(23): 4127–4132. 3. Kamiya R, Cheeseman BA, Popper P and Chou TW. Some recent advances in the fabrication and design of three-dimensional textile preforms: a review. Comps Sci Tech 2000; 60(1): 33–47. 4. Go Q, Zhang Y, Ming R and Chen L. 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Singh et al. 6685S Appendix List of Abbreviation 3D Three-dimensional 2D Two-dimensional DREF Double drum based friction spinning system developed by Dr. ESF Electromagnetic shielding fabric EM Electromagnetic EMS Electromagnetic shielding EMSE Electromagnetic shielding effectiveness FSMS Free space measurement system GHz Gigahertz PPS Polyphenylene sulphide μ Relative magnetic permeability σ Relative conductivity f Frequency (H ) μ Frequency at amplitude without shielding μ Amplitude at same frequency point with a shield SE Shielding effectiveness due to reﬂection SE Shielding effectiveness due to absorption SE Shielding effectiveness

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Journal of Industrial Textiles – SAGE

Published: Jun 1, 2022

Keywords: Conductive yarns; electromagnetic shielding; orthogonal structure; polyphenylene sulfide; reflectance; transmittance

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Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

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Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

Optimization of electromagnetic shielding of three-dimensional orthogonal woven hybrid fabrics in ku band frequency region by response surface methodology

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