Multi-level metalized PBO composite fabric for polar extreme environments: integrating electromagnetic protection, stable electric thermal conversion, and high-strength

Polar scientific research equipment in extreme low-temperature and strong electromagnetic interference (EMI) environments imposes multiple stringent requirements on the electromagnetic protection, active thermal management, and structural reliability of materials. Fibrous fabric materials with metal-functionalized surfaces have great potential for application in polar scientific research. In this work, a multifunctional PBO@Ni@Cu (poly-p-phenylene benzobisoxazole@Ni@Cu) composite fabric was developed. The composite was based on PBO fibers, through optimized sequential electroless nickel plating and copper electroplating processes for depositing Ni and Cu layers. Remarkably, the tensile strength of PBO@Ni@Cu remained at 5.16 GPa. The resulting material exhibited an excellent electromagnetic shielding performance of 59.57 dB in the X-band and achieved stable surface Joule heating at 195 °C under an applied voltage of 2 V. To address its high reflectivity, annealing combined with polydimethylsiloxane coating treatment was implemented, increasing the absorption coefficient to 0.35 while maintaining an effective shielding performance of 43.74 dB, which significantly reduced secondary EMI reflections. Notably, in polar environments, this composite not only shields unmanned aerial vehicle components from electromagnetic waves but also facilitates deicing/anti-icing functions of rotor blades through electro-thermal conversion, thereby ensuring flight stability. Additionally, PBO@Ni@Cu provides stable electromagnetic protection and body temperature maintenance for polar researchers working outdoors. This study provides a multifunctional material solution for multi-scenario applications in high-cold and strong electromagnetic interference environments.