Investigation of flexible warp-knitted metal meshes for electromagnetic interference shielding

This paper develops four novel warp-knitted structures with two bars of the one-in one-out threading mode and describes the investigation of electromagnetic interference (EMI) shielding metal meshes composed of contiguous ultra-fine metal wires fabricated using warp-knitting technology. The mechanical properties, electrical conductivity, and microwave shielding effectiveness (SE) of the flexible meshes are assessed in terms of the mesh structure, mesh material, and warp run-in parameter. The results reveal that the metal mesh has a flexible and stable mechanical property, good electrical conductivity, and optimal EMI performance when the mesh structure is open lap atlas. The gold-coated molybdenum mesh exhibits the lowest electrical resistivity (5.18 × 10 ⁻⁵ ohm/sq) and optimal average EMI SE (–21.04 dB), making it a candidate for EMI shields for intelligent wearable electronic devices. The warp run-in can adjust the EMI SE, and the optimum average EMI SE (–25.52 dB) can be obtained when the warp run-in is set at the 2580 rack. Moreover, the warp-knitted metal meshes show desirable EMI shielding efficiency persisting at >70% even at large strain deformations and under cyclic bending and twisting deformations. Conductive warp-knitted meshes with a millimeter period and micron-scale wire diameter exhibit an adequately large scale, satisfactory mechanical stability, excellent flexibility, permanent conductivity, and strong microwave reflection, simultaneously. Moreover, the EMI SE of warp-knitted metal mesh reaches the protection level (–20 dB) prescribed by standard electronic devices. Therefore, the warp-knitted metal meshes show great potential in flexible and wearable EMI shielding devices.