Scalable fabrication of conductive fabrics via spray-coated polyaniline–carbon nanotube emulsion paints for wearable applications

Electrically conductive paint was developed through emulsion polymerization of aniline, followed by incorporation of carboxylated carbon nanotubes (CNTs) . The paint was optimized by systematically varying polymerization time , temperature , oxidant/aniline molar ratio , and DBSA/aniline molar ratio . Then, 5 wt% functionalized CNTs were incorporated, resulting in maximum conductivity and coating stability. Prior to coating, polyester fabrics were pretreated with concentrated sulfuric acid to introduce surface roughness and polar groups, thereby enhancing adhesion and durability of the conductive layer. The optimized paint exhibited a surface resistivity of 4.34 Ω/cm2 on polyester fabric while maintaining flexibility , mechanical integrity, improved coating adhesion and wash durability. Among the tested solvents , xylene and hexane-based formulations showed excellent shelf stability up to two months, whereas HCl-based paint offered higher conductivity but lower storage stability. This scalable spray-coating approach provides a practical route to fabricate durable conductive textiles for wearable and flexible electronic applications.