Kevlar reinforced carbon nanotube fabrics for EMI shielding: Scalable solutions for industrial and occupational protection

Pristine carbon nanotube (CNT) fabric and Kevlar-reinforced CNT-silicone fabric were fabricated using a modified continuous floating catalyst chemical vapor deposition synthesis process. This scalable method produced fabrics measuring 25 cm × 90 cm, with thickness controlled via synthesis time. The CNT-based fabrics were flexible, electrically conductive, and reinforced with Kevlar yarn, fabric, or veil materials. Single-layer configurations exhibited electromagnetic interference (EMI) shielding effectiveness (SE) between 25 to 65 dB in the 8–12 GHz frequency range. Notably, multilayered assemblies of pristine CNT and CNT–silicone/Kevlar composite fabrics achieved an EMI SE of approximately 80 dB – one of the highest reported for CNT-based materials. These fabrics can be seamlessly incorporated into textiles and garments using conventional fabrication techniques. To demonstrate their practical applicability, an EMI shielding wallet was fabricated by stitching these fabrics together. Overall, this study presents high-performance EMI shielding fabrics with tunable specific shielding effectiveness ranging from 3,700 to 70,000 dB·cm 2 /g, making them highly adaptable for various applications in defense, aerospace, communication, occupational safety, and industrial settings. Furthermore, the findings reinforce the notion that while electrical conductivity significantly influences EMI SE, it is not the sole determining factor.