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Electroless Nickel Plated Composite Textile Materials for Electromagnet Compatibility

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Electroless Nickel Plated Composite Textile Materials for Electromagnet Compatibility Indian Journal of .Fibre & Textile Research Vol. 36, March 2011, pp. 35-41 Electroless nickel plated composite textile materials for electromagnet compatibility R Perumalraj a Bannari Amman Institute of Technology, Sathyamangalam 638 401, India and B S Dasaradan Department of Textile Technology, P.S.G. College of Technology, Peelamedu, Coimbatore 641 004, India Received 16 April 2010; revised received and accepted 8 June 2010 A study on electromagnetic shielding effectiveness of electroless nickel plated copper core with polyester sheath yarn composite fabrics through Taguchi design and ANOVA has been reported. The electromagnetic shielding effectiveness of these conductive composite fabrics has been measured in the frequency range 200 - 1000 MHz using network analyzer equipment. It is observed that with an increase in palladium chloride and nickel (II) sulphate concentrations, the shielding effectiveness increases. The ANOVA results show that the time and temperature are negligible factors as compared to other factors. Keywords: Composite fabric, Core yarn, Copper, Dref II Spinning, Electromagnetic wave, Nickel plating, Polyester, Shielding 1 Introduction most polymer composites used for household Electromagnetic shielding provides protection by electrical and electronic devices are electrically reducing signals to levels at which they no longer insulating and transparent to electromagnetic radiation affect equipment or can no longer be received 1. This and electrostatic discharge (ESD). The potential is achieved by reflecting and absorbing the radiation. health hazards (e.g. cancer) associated with exposure Polymeric composites are extensively used as passive to electromagnetic fields 12-17 are also the matter of and active elements in some electrical circuit concerned. To shield and limit against EMI and ESD, components in different technological applications 2, 3 conductive polymer composites started replacing due to their light weight, easy process ability, coated materials for various shielding applications in flexibility, corrosion resistance and cost-effectiveness. the electrical and electronic industries, especially for But elastomers and plastics contain very low electronic household materials. This trend has been concentrations of free charge carriers. They are driven mainly because of the better characteristics of electrically non-conductive and transparent to these polymers in terms of ESD, shielding from EMI, electromagnetic radiation. To provide conductivity thermal expansion, density, and chemical (corrosion and shielding from Electromagnetic Interference and oxidation resistance) properties 18-22 . However, (EMI), incorporation of fillers of high intrinsic conductive polymers have rigid characteristics owing conductivity such as particulate carbon blacks, carbon to their chemical conformation of benzene rings, and graphite fibres, or metal powder to the polymer making their formation difficult. A few studies have matrix is required 4,5 . The amount of electrically reported conductive knitted fabrics reinforced conductive filler required to impart high electrical composites as electromagnetic shielding effectiveness conductivity to an insulating polymer can be (EMSE) and ESD materials. Previously, Cheng et al . 23-26 dramatically decreased by the selective localization of fabricated some knitted fabric reinforced the filler in one phase, or best at the interface of a polypropylene composites for use as EMSE and ESD continuous two-phase polymer blend 6-11 . Unfortunately, materials, and indicated that the knitted fabric reinforced polymer composites are suitable for —————— aTo whom all the correspondence should be addressed. making complex shaped components and application E-mail: [email protected] in electromagnetic shielding 36 INDIAN J. FIBRE TEXT. RES., MARCH 2011 The coating of fabrics is a textile finishing process parameters to improve the EMSE of copper core yarn that adds to the value and improves functions 27 . With with polyester sheath composite fabric through the advent of synthetic fibres, there are now less Taguchi design and ANOVA. expensive ways to make metallic fabrics in the twenty-first century. Metallized fabric, in particular, 2 Materials and Methods has an identity and a quality of brightness that can The fabrics from complex copper core spun yarns create beautifully reflected and lustrous images. The (179 tex) with polyester sheath (copper wire diameter, reflective surfaces can offer a unique appearance as a 0.12mm and core: sheath ratio of copper and result of this technical process and metalized fabrics polyester, 23 : 77) were produced on Dref-II friction are very popular in both the contemporary consumer spinning machines. These copper core / polyester market and in technical applications. Metalized fabric sheath yarns were converted into plain woven fabric has been produced by a laminating process between and the fabric was then treated with electroless nickel metal powder or foil and fabric with binder 28 . plating as per Taguchi design to improve the EMSE Vacuum deposition and sputtering coating processes of composite fabric. In the EN plating process, the have been applied to polyester fabric with aluminium, driving force for the reduction of nickel metal ions titanium and stainless steel 29 and a silver-plated and their deposition is supplied by a chemical product was usually produced by electroplating on the reducing agent in solution. This driving potential is surface of conductive materials 30,31 . essentially constant at all points of the surface of the Electroless plating is a chemical reduction process component, provided the agitation is sufficient to which depends upon the catalytic reduction of a ensure a uniform concentration of metal ions and metallic ion in an aqueous solution containing a reducing agents. The EN plating process was reducing agent, and the subsequent deposition of the basically divided into five main stages, namely pre- metal without the use of electrical energy. The metals cleaning, sensitization, activation, electroless nickel capable of being deposited by electroless plating deposition and post-treatment. In the electroless include nickel, cobalt, copper, gold, palladium nickel plating process, unless otherwise stated, all and silver. chemicals used are of A R grade. Electroless nickel (EN) is an alloy of 88-99% 2.1 Pre-treatment nickel and the balance with phosphorous, boron, or a To facilitate the plating of metal particles on the few other possible elements. EN coatings, therefore, fabric surface, pre-treatment was carried out. The can be tailored to meet the specific requirements of an processes of pre-treatment consist of pre-cleaning, application with the proper selection of the nickel's sensitization and activation. alloying element(s) and their respective percentages in the plated layer. All varieties of EN, including Pre-cleaning composite EN coatings, can be applied to numerous Pre-cleaning is done for operating the electroless substrates including metals, alloys, and nonconductors nickel solution so that required properties are obtained with outstanding uniformity of coating thickness to in the fabric. Additives and/or contaminants can have complex geometries. a profound effect on performance, as will operate Diligent control of the solution's stabilizer content, conditions. In this process, all fabric samples were pH, temperature, tank maintenance, loading, and pre-cleaned in a 2% non-ionic detergent at pH 7 and freedom from contamination are essential for its temperature 40°C for 20 min. Deionised water was reliable operation. EN solutions are highly surface then used to rinse the pre-cleaned samples. Triton X- area dependent. Surface areas are introduced to the 100 as a non-ionic detergent was used. solution by the tank itself, in-tank equipment, immersed substrates, and contaminants. Continuous Sensitisation filtration, often sub-micron, of the solution at a rate of Sensitisation is a process of catalyzing the non- atleast ten turnovers per hour is always recommended conductive substrate. This enables the fabric surface to avoid particle contamination which could lead to to act as a catalyst for the deposition of nickel. The solution decomposition or imperfections in the plated auto-catalysation is obtained through this process. In layer. In this study, attempts have been made to the case of sensitizing fabric surfaces, the cleaned optimize the electroless nickel plated process fabric samples were subjected to the surface sensitizer PERUMALRAJ & DASARADAN: ELECTROLESS NICKEL PLATED COMPOSITE TEXTILE MATERIALS 37 (mixture of 5 g/L stannous chloride and 5M/L hydrochloric acid) with slow agitation for 10 min at 25°C and 1 pH. In sensitization, non-conductive substrate absorbs the stannous Sn 2+ ions from the stannous solution. Activation Activation is carried out for activating the fabric surface for the nickel deposition. The objective of this process is same as that of sensitization. In this process, a activator solution is used. The sensitized fabrics were rinsed with deionised water subsequently and then immersed in the activator solution [palladium (II) chloride, hydrochloric acid (conc. 37%) and boric acid] at pH 2 and 25°C for 5 min in order to achieve Fig. 1—Palladium cluster enveloped by stannous chloride layers surface activation. The activated fabrics were rinsed solutions results in electroless nickel plating as with deionised water afterwards. demonstrated. After this, nickel particles are adhered In activation,
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