Improving the anti‐impact performance of ultra‐high molecular weight polyethylene fabric intercalated with carbon nanotubes and shear thickening fluid

Abstract Ultra‐high molecular weight polyethylene (UHMWPE) is commonly used with many layers to realize protection and this can greatly benefit from advancements in fabric mechanical properties. This research introduces an innovative approach to crafting a composite felt, leveraging UHMWPE fabric, carbon nanotubes (CNTs), shear thickening fluid (STF), and polyvinyl alcohol (PVA) binder through a spray technique. The method results in a fabric with exceptional tensile strength and anti‐impact characteristics. Observations during the fabrication process reveal profound surface morphology alterations, showcasing an intricate layering of PVA binder, CNTs, and STF that seamlessly encapsulates each component of the STF/CNTs/UHMWPE system. The tensile strength and anti‐impact properties including punch residual velocity and energy absorbed are 564.0 ± 12.4 MPa, 1.537 ± 0.032 m/s and 22.952 ± 1.158 J in 12 ms, increased by 143.3%, 24.3% and 193.3%, respectively, compared to neat UHMWPE. This substantial performance uplift is attributed to multiple factors: the reinforcing friction between fibers/yarns fostered by the PVA binder and the full or partial embedding of CNTs, the additional reinforcing strength imparted by the CNTs matrix, and the dynamic viscosity enhancement of STF under impact forces. Highlights Anti‐impact felt was prepared by spraying PVA, CNTs, and STF onto UHMWPE. The tensile strength of anti‐impact felt was improved by 143.3%. The energy absorbed and impact depth was raised by 193.3%. The enhanced friction between fibers is caused by PVA and CNTs. The strength of CNTs and increased viscosity of STF under impact are notable.