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Of late, a significant amount of research has been carried out using metals for conductive fabrics and composites to obtain the desired level of electromagnetic shielding along with physical and mechanical properties for its durability. However, incorporating these metallic filaments as core or as an integral part of core deteriorate the mechanical properties of textile yarns and ultimately the fabrics’. Moreover, the transparency of fabrics to high frequency/smaller wavelength waves further increases with the attempt to increase the metallic filament diameter. This study, therefore analyses the effects of metallic filament alignment in order to improve the mechanical properties of the resultant hybrid yarns, and devises an alternative method to increase the amount of conductive filament without increasing the diameter of the conducting wire in hybrid yarn structures. The results suggest that the tensile properties of the proposed hybrid cover yarns with conductive filament as covering component is superior as compared to the yarns having a conductive filament in the core, however, the electrical resistance increases with an increase in conductive filament length. The tenacity, elongation and initial modulus values were enhanced several times by incorporating the conductive filament as spiral covering. Moreover, with the proposed alignment method, the amount of copper in hybrid yarn can be increased up to some extent by changing the number of turns of covering component.

Effects of metal filament’s alignment on tensile and electrical properties of conductive hybrid cover yarns