Lightweight polypropylene/stainless-steel fiber composite foams with low percolation for efficient electromagnetic interference shielding

Ultrastrong MXene film induced by sequential bridging with liquid metal

Assembling titanium carbide (Ti3C2Tx) MXene nanosheets into macroscopic films presents challenges, including voids, low orientation degree, and weak interfacial interactions, which reduce mechanical performance. We demonstrate an ultrastrong macroscopic MXene film using liquid metal (LM) and bacterial cellulose (BC) to sequentially bridge MXene nanosheets (an LBM film), achieving a tensile strength of 908.4 megapascals. A layer-by-layer approach using repeated cycles of blade coating improves the orientation degree to 0.935 in the LBM film, while a LM with good deformability reduces voids into porosity of 5.4%. The interfacial interactions are enhanced by the hydrogen bonding from BC and the coordination bonding with LM, which improves the stress-transfer efficiency. Sequential bridging provides an avenue for assembling other two-dimensional nanosheets into high-performance materials.

High green index electromagnetic interference shields with semiconducting Bi2S3 fillers in a PEDOT:PSS matrix

Conventional metallic electromagnetic interference (EMI) shields, as well as the emerging 2D material-based shields, meet the shielding effectiveness (SE) needs of most applications. However, their shielding performance is dominated by the reflection of incoming radiation due to their high electrical conductivity, which leads to secondary pollution. This problem is getting exacerbated with the proliferation of electronics and communication networks in modern society. Thus, EMI shields that function dominantly by the absorption of incoming radiation are highly desirable. Such shields would be characterized by a green index, which is the ratio of absorbance over reflectance, close to or greater than one. For nonmagnetic materials, the best way to reduce the undesirable large impedance mismatch is to reduce the effective permittivity of the shield material. Here, we present a new EMI shield with a semiconductor Bi2S3 filler in a conducting PEDOT:PSS polymer matrix, instead of the conventional conductive fillers, to reduce the effective permittivity and demonstrate that even a light loading of only 10% Bi2S3 provides high SE of over 40 dB with a green index value of 0.75. Increasing the filler content to 15 wt% increases the green index close to unity while dropping the SE to 30 dB. The shielding mechanism is explained through electromagnetic parameter measurements and supplemented by density functional theory calculations. This work lays the foundation for the advancement of lightweight and ultrathin green EMI shields with minimum secondary pollution.

Multi-Functional and Flexible Nano-Silver@MXene Heterostructure-Decorated Graphite Felt for Wearable Thermal Therapy

Wearable heaters with multifunctional performances are urgently required for the future personal health management. However, it is still challengeable to fabricate multifunctional wearable heaters simultaneously with flexibility, air-permeability, Joule heating performance, electromagnetic shielding property, and anti-bacterial ability. Herein, silver nanoparticles (AgNPs)@MXene heterostructure-decorated graphite felts are fabricated by introducing MXene nanosheets onto the graphite felts via a simple dip-coating method and followed by a facile in situ growth approach to grow AgNPs on MXene layers. The obtained AgNPs@MXene heterostructure decorated graphite felts not only maintain the intrinsic flexibility, air-permeability and comfort characteristics of the matrixes, but also present excellent Joule heating performance including wide temperature range (30-128 °C), safe operating conditions (0.9-2.7 V), and rapid thermal response (reaching 128 °C within 100 s at 2.7 V). Besides, the multifunctional graphite felts exhibit excellent electromagnetic shielding effectiveness (53 dB) and outstanding anti-bacterial performances (>95% anti-bacterial rate toward Bacillus subtilis, Escherichia coli and Staphy-lococcus aureus). This work sheds light on a novel avenue to fabricate multifunctional wearable heaters for personal healthcare and personal thermal management.

Porous Gradient Composite with Dependable Superhydrophobic Protection for Multifunctional Electromagnetic Interference Shielding

Simultaneously realizing high electromagnetic interference (EMI) shielding and superhydrophobic properties of materials to ensure long-term stability in harsh environments is a very challenging task. In this work, an efficient superhydrophobic EMI shielding composite with a gradient conductivity and porous structure was prepared by chemical plating, in situ polymerization, and spraying processes. Benefiting from the structural characteristics of porous multilayers and the rational distribution of electromagnetic two-component fillers in the composite, as well as the synergistic effect of various electromagnetic loss mechanisms, a perfect unification of high EMI shielding effectiveness of 62 dB and high absorption coefficient (A) of 0.77 was achieved. Meanwhile, a thin layer with further enhanced impedance matching was constructed on the surface of the composite using double-sized mixed particles of Fe3O4 and graphite particles (GP) in conjunction with the spraying process. The rough surface microstructure of the thin layer bestows the composite superhydrophobicity, and even after long-term immersion in acidic and alkali solutions or repetitive bending, the water contact angle still remains at a high level. Additionally, the sprayed materials also endow the composite with outstanding photothermal conversion properties that enhance the ability to adapt to environmental changes, significantly raising the practical application value.

Enhancement of Electromagnetic Wave Shielding Effectiveness by the Incorporation of Carbon Nanofibers-Carbon Microcoils Hybrid into Commercial Carbon Paste for Heating Films

Carbon microcoils (CMCs) were formed on stainless steel substrates using C₂H₂ + SF₆ gas flows in a thermal chemical vapor deposition (CVD) system. The manipulation of the SF₆ gas flow rate and the SF₆ gas flow injection time was carried out to obtain controllable CMC geometries. The change in CMC geometry, especially CMC diameter as a function of SF₆ gas flow injection time, was remarkable. In addition, the incorporation of H₂ gas into the C₂H₂ + SF₆ gas flow system with cyclic SF₆ gas flow caused the formation of the hybrid of carbon nanofibers-carbon microcoils (CNFs-CMCs). The hybrid of CNFs-CMCs was composed of numerous small-sized CNFs, which formed on the CMCs surfaces. The electromagnetic wave shielding effectiveness (SE) of the heating film, made by the hybrids of CNFs-CMCs incorporated carbon paste film, was investigated across operating frequencies in the 1.5-40 GHz range. It was compared to heating films made from commercial carbon paste or the controllable CMCs incorporated carbon paste. Although the electrical conductivity of the native commercial carbon paste was lowered by both the incorporation of the CMCs and the hybrids of CNFs-CMCs, the total SE values of the manufactured heating film increased following the incorporation of these materials. Considering the thickness of the heating film, the presently measured values rank highly among the previously reported total SE values. This dramatic improvement in the total SE values was mainly ascribed to the intrinsic characteristics of CMC and/or the hybrid of CNFs-CMCs contributing to the absorption shielding route of electromagnetic waves.

Progress in the Foaming of Polymer-based Electromagnetic Interference Shielding Composites by Supercritical CO2

As a critical action plan formulated for peaking carbon dioxide emissions, polymeric electromagnetic interference (EMI) shielding materials based on CO₂ foaming technology have recently been attracting widespread attention in both research and industry, attributable to their efficient use of CO₂ , high specific strength, corrosion resistance and low-cost characteristics. In the past decade, the emergence of novel design concepts and preparation techniques for CO₂ foaming technology has led to the development of new high-performance EMI shielding materials in this field. This review summarizes the research progress made to date on the fabrication of EMI shielding composite foams by supercritical carbon dioxide (scCO₂ ) foaming. We also explore the structure-activity relationships between the component/distribution and EMI shielding properties. Additionally, the application prospects and development challenges of new EMI shielding composite foams are described.

Research of Ferric Ion Regulation on a Polyimide/C-MXene Microcellular Composite Film

This paper established a new kind of polyimide/C-MXene composite films with a microcellular structure for electromagnetic interference shielding through solution mixing and liquid phase separation methods. Polyimide was used as the resin material, Ti₃C₂T_x MXene was used as the electromagnetic wave-shielding medium, l-citrulline was used as the surface modification agent, ferric trichloride (especially the ferric ion) was used as the cross-linking agent between the polyimide and modified C-MXene, and a microcell was used as the shielding structure. By adjusting the content of ferric ions, the foam structure, mechanical properties, thermal conductivity, and electromagnetic interference shielding efficiency of the polyimide/C-MXene microcellular composite film could be controlled. The higher the ferric ion content, the smaller the foam size and the higher the electromagnetic interference shielding efficiency. With increasing ferric ion content, the tensile strength and Young's modulus appeared to first increase and then decrease; when the ferric ion content was 0.8 wt %, the tensile strength and Young's modulus reached their maximum values, which were 10.06 and 325.29 MPa, respectively. In addition, with increasing ferric ion content, the thermal insulation showed first decreasing and then increasing tendency; the lowest thermal conductivity was 0.17 W/(m·K) when the ferric ion content was 0.8 wt %.

Mechanical Response of Fiber-Filled Automotive Body Panels Manufactured with the Ku-FizzTM Microcellular Injection Molding Process

To maximize the driving range and minimize the associated energy needs and, thus, the number of batteries of electric vehicles, OEMs have adopted lightweight materials, such as long fiber-reinforced thermoplastics, and new processes, such as microcellular injection molding. These components must withstand specific loading conditions that occur during normal operation. Their mechanical response depends on the fiber and foam microstructures, which in turn are defined by the fabrication process. In this work, long fiber thermoplastic door panels were manufactured using the Ku-Fizz^TM microcellular injection molding process and were tested for their impact resistance, dynamic properties, and vibration response. Material constants were compared to the properties of unfoamed door panels. The changes in mechanical behavior were explained through the underlying differences in their respective microstructures. The specific storage modulus and specific elastic modulus of foamed components were within 10% of their unfoamed counterparts, while specific absorbed energy was 33% higher for the foamed panel by maintaining the panel's mass/weight.

Transportable, Endurable, and Recoverable Liquid Metal Powders with Mechanical Sintering Conductivity for Flexible Electronics and Electromagnetic Interference Shielding

Liquid metals (LMs, e.g., EGaIn) promise a vast potential in accelerating the development of flexible electronics, smart robots, and wearable and biomedical devices. Although a variety of emerging processing methods are reported, they suffer several risks (e.g., leakage, weak adhesion, and low colloidal and chemical stability) because of their excellent fluidity, high surface tension, and rapid oxidation. Herein, liquid metal powders (LMPs) are fabricated based on a versatile method by vigorously stirring EGaIn with nonmetallic or organic particles through interfacial interactions. During the mixing process, EGaIn microdroplets are wrapped with a nonmetallic or an organic shell by electrostatic adsorption, and a more sticky oxide layer is constantly generated and then broken owing to the shearing friction. These transportable powders exhibit superior stability under extreme conditions (e.g., water and high temperature), being capable of recovering electrical conductivity and strong adhesion on different substrates upon mechanical sintering. A flexible, robust, and conductive coating can be constructed via swabbing with an integrated Joule heating effect and excellent electromagnetic interference shielding performances, and it is applicable in flexible wearable electronics, microcircuits, and wireless power transmission systems.

A Comparative Study on Bio-Based PU Foam Reinforced with Nanoparticles for EMI-Shielding Applications

Today, most commercial polyols used to make polyurethane (PU) foam are produced from petrochemicals. A renewable resource, castor oil (CO), was employed in this study to alleviate concerns about environmental contamination. This study intends to fabricate a bio-based and low-density EMI-defending material for communication, aerospace, electronics, and military appliances. The mechanical stirrer produces the flexible bio-based polyurethane foam and combines it with nanoparticles using absorption and hydrothermal reduction processes. The nanoparticles used in this research are graphite nanoplates (GNP), zirconium oxide (ZrO₂), and bamboo charcoal (BC). Following fabrication, the samples underwent EMI testing using an EMI test setup with model number N5230A PNA-L. The EMI experimental results were compared with computational simulation using COMSOL Multiphysics 5.4 and an optimization tool using response surface methodology. A statistical design of the experimental approach is used to design and evaluate the experiments systematically. An experimental study reveals that a 0.3 weight percentage of GNP, a 0.3 weight percentage of ZrO₂, and a 2.5 weight percentage of BC depict a maximum EMI SE of 28.03 dB in the 8–12 GHz frequency band.

Recent Progress in Electromagnetic Interference Shielding Performance of Porous Polymer Nanocomposites—A Review

The urge to develop high-speed data transfer technologies for futuristic electronic and communication devices has led to more incidents of serious electromagnetic interference and pollution. Over the past decade, there has been burgeoning research interests to design and fabricate high-performance porous EM shields to tackle this undesired phenomenon. Polymer nanocomposite foams and aerogels offer robust, flexible and lightweight architectures with tunable microwave absorption properties and are foreseen as potential candidates to mitigate electromagnetic pollution. This review covers various strategies adopted to fabricate 3D porous nanocomposites using conductive nanoinclusions with suitable polymer matrices, such as elastomers, thermoplastics, bioplastics, conducting polymers, polyurethanes, polyimides and nanocellulose. Special emphasis has been placed on novel 2D materials such as MXenes, that are envisaged to be the future of microwave-absorbing materials for next-generation electronic devices. Strategies to achieve an ultra-low percolation threshold using environmentally benign and facile processing techniques have been discussed in detail.

In Situ Foam 3D Printing of Microcellular Structures Using Material Extrusion Additive Manufacturing

A facile manufacturing method to enable the in situ foam 3D printing of thermoplastic materials is reported. An expandable feedstock filament was first made by incorporation of thermally expandable microspheres (TEMs) in the filament during the extrusion process. The material formulation and extrusion process were designed such that TEM expansion was suppressed during filament fabrication. Polylactic acid (PLA) was used as a model material, and filaments containing 2.0 wt % triethyl citrate and 0.0-5.0 wt % TEM were fabricated. Expandable filaments were then fed into a material extrusion additive manufacturing process to enable the in situ foaming of microcellular structures during layer deposition. The mesostructure, cellular morphology, thermal behavior, and mechanical properties of the printed foams were investigated. Repeatable foam prints with highly uniform cellular structures were successfully achieved. The part density was reduced with an increase in the TEM content, with a maximum reduction of 50% at 5.0 wt % TEM content. It is also remarkable that the interbead gaps of mesostructure vanished due to the local polymer expansion during in situ foaming. The incorporation of TEM and plasticizer only slightly lowered the critical temperatures of PLA, that is, glass-transition, melting, and decomposition temperatures. Moreover, with the introduction of foaming, the specific tensile strength and modulus decreased, whereas the ductility and toughness increased severalfold. The results unveil the feasibility of a novel additive manufacturing technology that offers numerous opportunities toward the manufacturing of specially designed structures including functionally graded foams for a variety of applications.

Lightweight electromagnetic interference shielding poly(L-lactic acid)/poly(D-lactic acid)/carbon nanotubes composite foams prepared by supercritical CO2 foaming

Lightweight and biodegradable polymer composites with efficient electromagnetic interference (EMI) shielding performance are of great significance for controlling pollution caused by plastic waste and electromagnetic radiation. Herein, poly(lactic acid) (PLA)/carbon nanotubes (CNTs) composites were prepared through a melt blending method. By adding a small amount of poly(D-lactic acid) to poly(L-lactic acid) (PLLA), the EMI shielding performance of the composites was improved because an enhanced viscoelasticity and suitable crystallinity could help to construct fine CNT conductive networks. When the PDLA content was 2 wt%, the EMI shielding effectiveness (SE) of the PLLA-2PDLA-10CNTs reached 27.1 dB at 26.5 GHz. Based on these findings, a green supercritical CO₂ foaming method was employed to prepare lightweight PLLA/PDLA/CNTs composites. For the PLLA-2PDLA-10CNTs foams, when the expansion ratio was 1.24, the EMI SE was 20.1 dB at 26.5 GHz. In addition, the EMI shielding mechanism of the foams was dominated by absorption. This paper provides a facile way to prepare lightweight and environmentally friendly materials for EMI shielding applications.

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

Due to their light-weight and cost-effectiveness, cellular thermoplastic foams are considered as important engineering materials. On the other hand, additive manufacturing or 3D printing is one of the emerging and fastest growing manufacturing technologies due to its advantages such as design freedom and tool-less production. Nowadays, 3D printing of polymer compounds is mostly limited to manufacturing of solid parts. In this context, a merged foaming and printing technology can introduce a great alternative for the currently used foam manufacturing technologies such as foam injection molding. This perspective review article tackles the attempts taken toward initiating this novel technology to simultaneously foam and print thermoplastics. After explaining the basics of polymer foaming and additive manufacturing, this article classifies different attempts that have been made toward generating foamed printed structures while highlighting their challenges. These attempts are clustered into 1) architected porous structures, 2) syntactic foaming, 3) post-foaming of printed parts, and eventually 4) printing of blowing agents saturated filaments. Among these, the latest approach is the most practical route although it has not been thoroughly studied yet. A filament free approach that can be introduced as a potential strategy to unlock the difficulties to produce printed foam structures is also proposed.

Ultrahigh and Tunable Electromagnetic Interference Shielding Performance of PVDF Composite Induced by Nano-Micro Cellular Structure

Lightweight and efficient electromagnetic interference (EMI) shielding materials play a vital role in protecting high-precision electronic devices and human health. Porous PVDF/CNTs/urchin-like Ni composites with different cell sizes from nanoscale to microscale were fabricated through one-step supercritical carbon dioxide (CO₂) foaming. The electrical conductivity and electromagnetic interference (EMI) shielding performance of the composites with different cell sizes were examined in detail. The results indicated that the nanoscale cell structure diminishes the EMI shielding performance of the composite, whereas the microscale cell structure with an appropriate size is beneficial for improving the EMI shielding performance. A maximum EMI shielding effectiveness (SE) of 43.4 dB was achieved by the composite foams which is about twice that of the solid composite. Furthermore, as the supercritical CO₂ foaming process reduces the density of the composite by 25–50%, the EMI SSE (specific shielding effectiveness)/t(thickness) of the composite reaches 402 dB/(g/cm²), which is the highest value of polymer foam obtained to the best of the authors’ knowledge. Finally, compression tests were performed to show that the composites still maintained excellent mechanical properties after the supercritical CO₂ foaming process.

Layered Foam/Film Polymer Nanocomposites with Highly Efficient EMI Shielding Properties and Ultralow Reflection

Lightweight, high-efficiency and low reflection electromagnetic interference (EMI) shielding polymer composites are greatly desired for addressing the challenge of ever-increasing electromagnetic pollution. Lightweight layered foam/film PVDF nanocomposites with efficient EMI shielding effectiveness and ultralow reflection power were fabricated by physical foaming. The unique layered foam/film structure was composed of PVDF/SiCnw/MXene (Ti₃C₂T_x) composite foam as absorption layer and highly conductive PVDF/MWCNT/GnPs composite film as a reflection layer. The foam layer with numerous heterogeneous interfaces developed between the SiC nanowires (SiCnw) and 2D MXene nanosheets imparted superior EM wave attenuation capability. Furthermore, the microcellular structure effectively tuned the impedance matching and prolonged the wave propagating path by internal scattering and multiple reflections. Meanwhile, the highly conductive PVDF/MWCNT/GnPs composite (~ 220 S m^-1) exhibited superior reflectivity (R) of 0.95. The tailored structure in the layered foam/film PVDF nanocomposite exhibited an EMI SE of 32.6 dB and a low reflection bandwidth of 4 GHz (R < 0.1) over the Ku-band (12.4 - 18.0 GHz) at a thickness of 1.95 mm. A peak SE_R of 3.1 × 10^-4 dB was obtained which corresponds to only 0.0022% reflection efficiency. In consequence, this study introduces a feasible approach to develop lightweight, high-efficiency EMI shielding materials with ultralow reflection for emerging applications.

Robust and Multifunctional Porous Polyetheretherketone Fiber Fabricated via a Microextrusion CO2 Foaming

Fabrication of multifunctional porous fibers with excellent mechanical properties has attracted abundant attention in the fields of personal thermal management textiles and smart wearable devices. However, the high cost and harsh preparation environment of the traditional solution-solvent phase separation method for making porous fibers aggravates the problems of resource consumption and environmental pollution. Herein, a microextrusion process that combines environmentally friendly CO₂ physical foaming with fused deposition modeling technology is proposed, via the dual features of high gas uptake and restricted cell growth, to implement the continuous production of porous polyetheretherketone (PEEK) fibers with a production efficiency of 10.5 cm s^-1 . The porous PEEK fiber exhibits excellent stretchability (234.8% strain) and good high-temperature thermal insulation property. The open-cell structure on the surface is favorable for the adsorption to achieve superhydrophobicity (154.4°) and high-efficiency photocatalytic degradation of rhodamine B (90.4%). Moreover, the parameterized controllability of the cell structure is beneficial to widening the multifunctional window. In short, the first porous PEEK physical foaming fiber, which opens up a new avenue for the application expansion, especially in the medical field, is realized.

A facile strategy for lightweight, anti-dripping, flexible polyurethane foam with low smoke emission tendency and superior electromagnetic wave blocking

Flexible polyurethane foam (FPUF) has been considered as an excellent material in many fields, such as furniture and electromagnetic interference (EMI) shielding products due to its lightweight and flexibility. However, there is a severe fire hazard problem for FPUF that makes it unsuitable to be used in practical. Herein, a facile method was to prepare anti-dripping FPUF via electroless plating at ambient temperature. The silver nanoparticles (SNPs) were in-situ grown on the surface along with the polydopamine (PDA) as an adhesive and template (SNP@PDA@FPUF). As a result, these FPUFs show outstanding fire safety and anti-dripping capacity, and the heat release rate reduced 80.92%. Furthermore, the amounts of carbon oxide (CO) and carbon dioxide (CO₂) decreased 75.01% and 22.4%, respectively. Above all, the EMI shielding effectiveness (SE) accomplished almost 120 dB as the increasing electroless time with a low density of 0.051 g/cm³. Furthermore, the specific EMI SE (SSE) and the absolute EMI SE (SSE/t) accomplished 2630.98 dB·cm³/g and 2434 dB·cm²/g, respectively, which was far beyond the commercial request. Therefore, this work may provide a facile way to prepare low density and EMI shielding products with high fire safety for next generation electronic products.

In-Situ Visualization of the Cell Formation Process of Foamed Polypropylene under Different Foaming Environments

In this paper, the dynamic foaming process of micro-foaming polypropylene (PP) in different foaming environments in real time was obtained via a visualization device. The relationship curve between cell number (n) and foaming time (t) was plotted, and then the nucleation kinetics of foam cells was analyzed. Results showed that the formation rate of cells changed obviously with the variation of melt temperature and the content of the foaming agent. The n-t curves presented a typical "S" shape, which indicated that the appearance of the cell number increased slowly in the initial foaming period, then increased rapidly in a short time, and finally maintained a certain value. When a certain pressure was applied to the PP melt, the external force had a great influence on the n-t curve. With the increasing external force, the rate of cell formation increased rapidly, and the shape of the n-t curve changed from "S" to "semi-S" without an obvious slow increase. The investigation of the n-t relationship in the PP dynamic foaming process under different foaming environments could provide effective bases for improving the foaming quality of injection molding foaming materials.

Layered Aluminum for Electromagnetic Wave Absorber with Near-Zero Reflection

Ideal electromagnetic (EM) wave absorbers can absorb all incident EM waves, regardless of the incident direction, polarization, and frequency. Absorptance and reflectance are intrinsic material properties strongly correlated with electrical conductivity; hence, achieving perfect absorptance with zero reflectance is challenging. Herein, we present a design strategy for preparing a nearly ideal EM absorber based on a layered metal that maximizes absorption by utilizing multiple internal reflections and minimizes reflection using a monotonic gradient of intrinsic impedance. This approach was experimentally verified using aluminum nanoflakes prepared via topochemical etching of lithium from Li₉Al₄, and the impedance-graded structure was obtained through the size-based sorting behavior of aluminum nanoflakes sinking in dispersion. Unlike in traditional shielding materials, strong absorption (26.76 dB) and negligible reflectivity (0.04 dB) with a ratio of >10³ can be achieved in a 120 μm thick film. Overall, our findings exhibit potential for developing a novel class of antireflective shielding materials.

Synthesis of high quality 2D carbide MXene flakes using a highly purified MAX precursor for ink applications

The practical application of 2D MXenes in electronic and energy fields has been hindered by the severe variation in the quality of MXene products depending on the parent MAX phases, manufacturing techniques, and preparation parameters. In particular, their synthesis has been impeded by the lack of studies reporting the synthesis of high-quality parent MAX phases. In addition, controllable and uniform deposition of 2D MXenes on various large-scale substrates is urgently required to use them practically. Herein, a method of pelletizing raw materials could synthesize a stoichiometric Ti₃AlC₂ MAX phase with high yield and processability, and fewer impurities. The Ti₃AlC₂ could be exfoliated into 1-2-atom-thick 2D Ti₃C₂T _x flakes, and their applicability was confirmed by the deposition and additional alignment of the 2D flakes with tunable thickness and electrical properties. Moreover, a practical MXene ink was fabricated with rheological characterization. MXene ink exhibited much better thickness uniformity while retaining excellent electrical performances (e.g., sheet resistance, electromagnetic interference shielding ability) as those of a film produced by vacuum filtration. The direct functional integration of MXenes on various substrates is expected to initiate new and unexpected MXene-based applications.

Hierarchical Porous Film with Layer-by-Layer Assembly of 2D Copper Nanosheets for Ultimate Electromagnetic Interference Shielding

The emergence of technologies, such as 5G telecommunication, electric vehicles, and wearable electronics, has prompted demand for ultrahigh-performance and cost-effective shielding materials to protect against both the potentially harmful effects of electromagnetic interference (EMI) on human health and electronic device operation. Here, we report hierarchical porous Cu foils via an assembly of single-crystalline, nanometer-thick, and micrometer-long copper nanosheets and their use in EMI shielding. Layer-by-layer assembly of Cu nanosheets enabled the formation of a hierarchically structured porous Cu film with features such as multilayer stacking; two-dimensional networking; and a layered, sheetlike void architecture. The hierarchical-structured porous Cu foil exhibited outstanding EMI shielding performance compared to the same thickness of dense copper and other materials, exhibiting EMI shielding effectiveness (SE) values of 100 and 60.7 dB at thicknesses of 15 and 1.6 μm, respectively. In addition, the EMI SE of the hierarchical porous Cu film was maintained up to 18 months under ambient conditions at room temperature and showed negligible changes after thermal annealing at 200 °C for 1 h. These findings suggest that Cu nanosheets and their layer-by-layer assembly are one of the promising EMI shielding technologies for practical electronic applications.

From Waste to Wealth: A Lightweight and Flexible Leather Solid Waste/Polyvinyl Alcohol/Silver Paper for Highly Efficient Electromagnetic Interference Shielding

With the popularization of 5G communications and the internet of things, electromagnetic wave (EW) radiation pollution has aroused much concern from the public, and the search for new materials and technologies for preparing electromagnetic shielding materials still continues all around the world. However, the contradiction among high shielding performance, economic applicability, and flexibility is still not well balanced. Herein, we fabricated a novel foldable leather solid waste (LSW)/polyvinyl alcohol (PVA)/silver (Ag) paper with excellent electromagnetic interference (EMI)-shielding ability using a facile but sustainable electroless plating (ELP) method with LSW as the resource. Taking PVA as a cross-linker, debundled leather fibers (LFs) generated by solid-state shearing milling could generate a flexible LSW/PVA substrate with a high specific surface area, and eventually the deposited Ag layer served as a protective layer not only to significantly improve the mechanical and thermal robustness, but also to endow the LSW/PVA/Ag paper with good hydrophobicity, which could protect from potential moisture damage. In addition to the reflection effect of metallic Ag on EW, the hierarchical structure of collagen fibers played an important role in superior high EMI-shielding effectiveness (∼55-∼90 dB) by an absorption-dominant EMI-shielding mechanism. Furthermore, a multilayer LSW/PVA/Ag paper was also prepared with enhanced EMI-shielding effectiveness of 111.3 dB benefited by constructing multiple reflection-absorption interfaces. The high-performance, environmentally friendly, and low-cost EMI-shielding materials not only offered a new avenue toward recycling LSW in a more value-added way, but also displayed promising potential for application in flexible shielding materials or wearable clothing.

Synergetic effect of crystal nucleating agent and melt self-enhancement of isotactic polypropylene on its rheological and microcellular foaming properties

Crystal nucleating agent Bis (3, 4- dimethylbenzylidene) sorbitol (DMDBS) was used to tune the melt strength and microcellular foaming properties of isotactic polypropylene (iPP) in this study. Rheological testing results reveal that the introduction of DMDBS could enhance the storage modulus and complex viscosity of iPP, obviously increase its crystallization onset temperature, compared to its counterparts without DMDBS. The addition of DMDBS could also significantly increase the cell nucleating ability of iPP, due to its large surface, cooperating with a thermal history control treatment. Quite fine microcellular iPP/DMDBS foams were fabricated with relatively small average cell sizes of nano to several micrometers, and cell densities up to 1011∼1012 cells/cm3, using the synergy effect of DMDBS and iPP’s melt self-enhancement. Under a comparatively low re-saturation pressure of 8 to 12 MPa, ideal microcellular foams could be generated, at a temperature zone of 158 to 162°C, which is slightly below to iPP’s original pellets nominal melting point.

High electromagnetic interference shielding of poly(ether-sulfone)/multi-walled carbon nanotube nanocomposites fabricated by an eco-friendly route

High-performance polymer matrix nanocomposites based on poly(ether-sulfone) (PES) matrix reinforced with multi-walled carbon nanotubes (MWCNTs) were fabricated using planetary ball mill followed by hot pressing. Their electrical properties and the electromagnetic interference shielding effectiveness (EMI-SE) were investigated and discussed. A percolation threshold of about 0.65 vol% MWCNT was obtained. The electrical conductivity was increased by more than ten orders of magnitude at the percolation threshold and to approximately 0.01 S cm^-1 at 6.67 vol% (or 10 wt%) MWCNT. This is a significant improvement. The highest EMI-SE of about 29-30 dB (both in the X-band and K_u-band) was obtained for the 6.67 vol% MWCNT filled nanocomposites with a thickness of 0.9 mm. The specific EMI-SE of these nanocomposites were found to be higher than the literature values. The thermal stability and the char yield (measured at 900 °C) of the nanocomposites were found to be more than 470 °C and 40.6%, respectively.

Thermoplastic Polyurethane/Lead Zirconate Titanate/Carbon Nanotube Composites with Very High Dielectric Permittivity and Low Dielectric Loss

Ternary composites of flexible thermoplastic polyurethane (TPU), lead zirconate titanate (PZT), and multiwalled carbon nanotubes (MWCNTs) with very high dielectric permittivity (εr) and low dielectric loss (tan δ) are reported. To assess the evolution of dielectric properties with the interactions between conductive and dielectric fillers, composites were designed with a range of content for PZT (0–30 vol%) and MWCNT (0–1 vol%). The microstructure was composed of PZT-rich and segregated MWCNT-rich regions, which could effectively prevent the formation of macroscopic MWCNT conductive networks and thus reduce the high ohmic loss. Therefore, εr increased by a maximum of tenfold, reaching up to 166 by the addition of up to 1 vol% MWCNT to TPU/PZT. More importantly, tan δ remained relatively unchanged at 0.06–0.08, a similar range to that of pure TPU. εr/tan δ ratio reached 2870 at TPU/30 vol% PZT/0.5 vol% MWCNT, exceeding most of the reported values. This work demonstrates the potential of three-phase polymer/conductive filler/dielectric filler composites for efficient charge storage applications.

Anomalous absorption of electromagnetic waves by 2D transition metal carbonitride Ti3CNT x (MXene)

Lightweight, ultrathin, and flexible electromagnetic interference (EMI) shielding materials are needed to protect electronic circuits and portable telecommunication devices and to eliminate cross-talk between devices and device components. Here, we show that a two-dimensional (2D) transition metal carbonitride, Ti₃CNT _x MXene, with a moderate electrical conductivity, provides a higher shielding effectiveness compared with more conductive Ti₃C₂T _x or metal foils of the same thickness. This exceptional shielding performance of Ti₃CNT _x was achieved by thermal annealing and is attributed to an anomalously high absorption of electromagnetic waves in its layered, metamaterial-like structure. These results provide guidance for designing advanced EMI shielding materials but also highlight the need for exploring fundamental mechanisms behind interaction of electromagnetic waves with 2D materials.

Superhigh Electromagnetic Interference Shielding of Ultrathin Aligned Pristine Graphene Nanosheets Film

Ultrathin, lightweight, high-strength, and thermally conductive electromagnetic interference (EMI) shielding materials with high shielding effectiveness (SE) are highly desired for next-generation portable and wearable electronics. Pristine graphene (PG) has a great potential to meet all the above requirements, but the poor processability of PG nanosheets hinders its applications. Here, efficient synthesis of highly aligned laminated PG films and nacre-like PG/polymer composites with a superhigh PG loading up to 90 wt% by a scanning centrifugal casting method is reported. Due to the PG-nanosheets-alignment-induced high electrical conductivity and multiple internal reflections, such films show superhigh EMI SE comparable to the reported best synthetic material, MXene films, at an ultralow thickness. An EMI SE of 93 dB is obtained for the PG film at a thickness of ≈100 µm, and 63 dB is achieved for the PG/polyimide composite film at a thickness of ≈60 µm. Furthermore, such PG-nanosheets-based films show much higher mechanical strength (up to 145 MPa) and thermal conductivity (up to 190 W m^-1 K^-1 ) than those of their MXene counterparts. These excellent comprehensive properties, along with ease of mass production, pave the way for practical applications of PG nanosheets in EMI shielding.

Magnetic-Electrospinning Synthesis of γ-Fe2O3 Nanoparticle-Embedded Flexible Nanofibrous Films for Electromagnetic Shielding

The exploration of a new family of flexible and high-performance electromagnetic shielding materials is of great significance to the next generation of intelligent electronic products. In this paper, we report a simple magnetic-electrospinning (MES) method for the preparation of a magnetic flexible film, γ-Fe₂O₃ nanoparticle-embedded polymeric nanofibers. By introducing the extra magnetic field force on γ-Fe₂O₃ nanoparticles within composite fibers, the critical voltage for spinning has been reduced, along with decreased fiber diameters. The MES fibers showed increased strength for the magnetic field alignment of the micro magnets, and the attraction between them assisted the increase in fiber strength. The MES fibers show modifications of the magnetic properties and electrical conductivity, thus leading to better electromagnetic shielding performance.

Advances in microcellular injection moulding

Injection moulding is a well-established replication process for the cost-effective manufacture of polymer-based components. The process has different applications in fields such as medical, automotive and aerospace. To expand the use of polymers to meet growing consumer demands for increased functionality, advanced injection moulding processes have been developed that modifies the polymer to create microcellular structures. Through the creation of microcellular materials, additional functionality can be gained through polymer component weight and processing energy reduction. Microcellular injection moulding shows high potential in creating innovation green manufacturing platforms. This review article aims to present the significant developments that have been achieved in different aspects of microcellular injection moulding. Aspects covered include core-back, gas counter pressure, variable thermal tool moulding and other advanced technologies. The resulting characteristics of creating microcellular injection moulding components through both plasticising agents and nucleating agents are presented. In addition, the article highlights potential areas for research exploitation. In particular, acoustic and thermal applications, nano-cellular injection moulding parts and developments of more accurate simulations.

Lightweight and Robust Carbon Nanotube/Polyimide Foam for Efficient and Heat-Resistant Electromagnetic Interference Shielding and Microwave Absorption

Excellent electromagnetic interference (EMI) shielding ability, light weight, and good heat resistance are highly required for practical applications of EMI shielding materials, such as in areas of aerospace, aircraft, and automobiles. Herein, a lightweight and robust carbon nanotube (CNT)/polyimide (PI) foam was developed for efficient and heat-resistant EMI shielding. Thanks to poly(vinyl pyrrolidone) (PVP) as a surfactant that not only promotes the uniform dispersion of CNTs to form perfect CNT conductive networks but also can be removed in situ during the polymerization process, the density of resultant CNT/PI foam is only 32.1 mg·cm^-3, and the EMI shielding effectiveness (EMI SE) is up to 41.1 dB, which represents one of the highest EMI SE values compared to previously reported polymer-based foams. The CNT/PI foam also achieves the absorption coefficient (A) of up to 82.3%, which is very impressive in CNT/polymer foams at comparable EMI SE levels. The PI matrix endows the foam with excellent heat resistance. The as-prepared CNT/PI foam presents a higher EMI SE than 35 dB even after being subjected to the flame of an alcohol burner. Moreover, the compressive strength and compressive modulus are up to 240.9 and 323.9 kPa. These results indicate its certain application potential in the harsh requirement of aeronautics and aerospace industries as a highly efficient and lightweight EMI shielding material.