Continuous Basalt Fabrics for Electromagnetic Interference Shielding Coated with In Situ Lubrication of Waterborne Polyurethane Containing Mn-Zn Ferrites

With rapid development of 5G/6G communication and high-power electronic devices, electromagnetic interference (EMI) shielding textiles are urgently required to mitigate electromagnetic pollution. Traditional metallic shielding suffered from heavy weight, poor corrosion resistance, and secondary electromagnetic reflection, while continuous basalt fibers (CBFs) exhibit excellent mechanical strength, lightweightness, thermal/chemical resistance, and electrical insulation, which makes CBFs ideal substrates for EMI devices. Herein, a multifunctional waterborne polyurethane (WPU) sizing agent (coating emulsion) integrated with Mn-Zn spinel ferrite was developed for in situ lubrication on the as-spun CBFs. The composite sizing agents consisted of a WPU matrix, water-soluble epoxy, mineral oil lubricant, CTAB surfactant, KH-570 coupling agent, and micro-sized Mn-Zn ferrites. Characterizations including particle size distribution, thermogravimetric analysis, water contact angle (WCA), water absorption, FTIR, XRD, and SEM were conducted to verify uniform anchoring of ferrites on the CBF surfaces. Increasing ferrite dosages induced slight particle aggregation, elevated surface hydrophobicity (WCA = 42.4° → 99.43°), and reduced water absorption (65% → 35%), which greatly improved the moisture resistance of the CBFs. The X-band EMI shielding tests revealed that the total shielding effectiveness (SET) of modified CBF fabrics increased from 0.11 dB (pristine fiber without ferrite) to 58.57 dB at a loading of 8.0 g/L ferrite. The absorption loss (SEA) dominated the shielding performance over reflection loss (SER). The low-to-moderate contents (1.5–3.0 g/L) of ferrite achieved ultra-high absorption, while higher ferrite loading (5.0–8.0 g/L) intensified the impedance mismatch and enhanced surface reflection. This work establishes a scalable fabrication of absorption-prioritized lightweight CBF shielding, which provides a feasible pathway for flexible EMI shielding textiles.