Roll-to-roll joule-heating to construct ferromagnetic carbon fiber felt for superior electromagnetic interference shielding

The effective safeguard from electromagnetic radiation damage via electromagnetic interference shielding (EMI) materials is crucial for diverse applications, especially in modern aerospace, medical, and human body protection endeavors. Despite great efforts have been made to surmount challenges encompassing scalability, sustainability and cost, the integrated and continuous production of large-area electromagnetic shielding materials remains unsolved for industrial-scale demands. Herein, we develop a cascaded methodology involving spray loading and Joule-heating for fabricating hybrid EMI fabric with superior efficiency, where ferromagnetic Fe3O4 nanoparticles are further successfully in situ deposition on ultralight carbon fiber felt (Fe3O4/FePc@CFF) in a roll-to-roll (R2R) manner. Fe3O4/FePc@CFF characterized by a surface density of only 64.76 g/m2, achieves specific shielding effectiveness per unit thickness (SSE/t) remarkable values of 9604 dB cm2 g−1 and 10947 dB cm2 g−1 within the X-band and Ku-band, respectively. Considering the high compatibility with assembly on flow line production, this research offers substantial development potential for further design and advancement of pivotal materials in the realm of electromagnetic protection. [Display omitted]