Development of Flexible EMI Shielded Materials

A novel plasma spray process allows for a highly metallic filled thermoplastic to be deposited on assorted cloth substrates, to create a flexible EMI construction material. Filler causing the EMI property to occur is dry-mixed into the thermoplastic, and the coating composition is created in situ on the cloth surface. Highly filled coatings are achievable, which previously have been denied due to rheological restrictions of using a high solids blend. Metallic fillers are proposed as the EMI shielding agent. Flexible, weather resistant thermoplastics are used as the bonding matrix for these active fillers. Excellent adhesion to the substrate is attained during the plasma process due to chemical grafting, which is caused by the plasma exposure. Cloth can be from any origin, although a synthetic fiber composition such as nylon, polyester, Nomex, or fluorinated polymer, would be preferred.