Structural Design for EMI Shielding: From Underlying Mechanisms to Common Pitfalls

Modern human civilization deeply relies on the rapid advancement of cutting-edge electronic systems that have revolutionized communication, education, aviation, and entertainment. However, the electromagnetic interference (EMI) generated by digital systems poses a significant threat to the society, potentially leading to a future crisis. While numerous efforts are made to develop nanotechnological shielding systems to mitigate the detrimental effects of EMI, there is limited focus on creating absorption-dominant shielding solutions. Achieving absorption-dominant EMI shields requires careful structural design engineering, starting from the smallest components and considering the most effective electromagnetic wave attenuating factors. This review offers a comprehensive overview of shielding structures, emphasizing the critical elements of absorption-dominant shielding design, shielding mechanisms, limitations of both traditional and nanotechnological EMI shields, and common misconceptions about the foundational principles of EMI shielding science. This systematic review serves as a scientific guide for designing shielding structures that prioritize absorption, highlighting an often-overlooked aspect of shielding science.

Surfactant-Mediated Highly Conductive Cellulosic Inks for High-Resolution 3D Printing of Robust and Structured Electromagnetic Interference Shielding Aerogels

Technological fusion of emerging three-dimensional (3D) printing of aerogels with gel processing enables the fabrication of lightweight and functional materials for diverse applications. However, 3D-printed constructs via direct ink writing for fabricating electrically conductive structured biobased aerogels suffer several limitations, including poor electrical conductivity, inferior mechanical strength, and low printing resolution. This work addresses these limitations via molecular engineering of conductive hydrogels. The hydrogel inks, namely, CNC/PEDOT-DBSA, featured a unique formulation containing well-dispersed cellulose nanocrystal decorated by a poly(3,4-ethylene dioxythiophene) (PEDOT) domain combined with dodecylbenzene sulfonic acid (DBSA). The rheological properties were precisely engineered by manipulating the solid content and the intermolecular interactions among the constituents, resulting in 3D-printed structures with excellent resolution. More importantly, the resultant aerogels following freeze-drying exhibited a high electrical conductivity (110 ± 12 S m-1), outstanding mechanical properties (Young's modulus of 6.98 MPa), and fire-resistance properties. These robust aerogels were employed to address pressing global concerns about electromagnetic pollution with a specific shielding effectiveness of 4983.4 dB cm2 g-1. Importantly, it was shown that the shielding mechanism of the 3D printed aerogels could be manipulated by their geometrical features, unraveling the undeniable role of additive manufacturing in materials design.

Highly flexible and ultrathin electromagnetic-interference-shielding film with a sandwich structure based on PTFE@Cu and Ni@PVDF nanocomposite materials

Light and flexible electromagnetic-interference-shielding materials are of great significance to control electromagnetic pollution and protect the human body and other nearby equipment or systems. In this study, a film of polytetrafluoroethylene wrapped with copper (PTFE@Cu) was prepared by depositing Cu using electroless plating on the surface of a microporous PTFE film modified by dopamine. A Ni@PVDF membrane was fabricated by casting a suspension of Ni nanochains in PVDF. The two kinds of films were hot-pressed into an ultrathin and efficient electromagnetic-shielding film with a sandwich structure. PTFE and PVDF provided high flexibility to the composite film, while the metal-wrapped polymer fiber structure gave the film an excellent electromagnetic-shielding efficiency, and the Ni nanochains and laminated hot-pressing process further enhanced the shielding ability of the film. Through these combined effects, the conductivity of the composite film reached 1117.57 S cm⁻¹ while the thickness was only about 80 μm, and the average shielding efficiency in the X-band range was as high as 57.16 dB with absorption accounting for about 67.2% of the total shielding. At the same time, the composite film had high strength and flexibility, and the tensile strength could reach 43.49 MPa. Even after bending 1000 times, the conductivity could still be maintained at 174.55 S cm⁻¹, while the average shielding effectiveness in the X-band range was retained at 44.29 dB. The film has great latent applications in flexible devices and portable wearable intelligent devices.

Light and flexible electromagnetic-interference-shielding materials are of great significance to control electromagnetic pollution and protect the human body and other nearby equipment or systems.

A Simple Approach to Control the Physical and Chemical Features of Custom-Synthesized N-Doped Carbon Nanotubes and the Extent of Their Network Formation in Polymers: The Importance of Catalyst to Substrate Ratio

This study intends to reveal the significance of the catalyst to substrate ratio (C/S) on the structural and electrical features of the carbon nanotubes and their polymeric nanocomposites. Here, nitrogen-doped carbon nanotube (N-MWNT) was synthesized via a chemical vapor deposition (CVD) method using three ratios (by weight) of iron (Fe) catalyst to aluminum oxide (Al₂O₃) substrate, i.e.,1/9, 1/4, and 2/3, by changing the Fe concentration, i.e., 10, 20, and 40 wt.% Fe. Therefore, the synthesized N-MWNT are labelled as (N-MWNTs)₁₀, (N-MWNTs)₂₀, and (N-MWNTs)₄₀. TEM, XPS, Raman spectroscopy, and TGA characterizations revealed that C/S ratio has a significant impact on the physical and chemical properties of the nanotubes. For instance, by increasing the Fe catalyst from 10 to 40 wt.%, carbon purity increased from 60 to 90 wt.% and the length of the nanotubes increased from 1.2 to 2.6 µm. Interestingly, regarding nanotube morphology, at the highest C/S ratio, the N-MWNTs displayed an open-channel structure, while at the lowest catalyst concentration the nanotubes featured a bamboo-like structure. Afterwards, the network characteristics of the N-MWNTs in a polyvinylidene fluoride (PVDF) matrix were studied using imaging techniques, AC electrical conductivity, and linear and nonlinear rheological measurements. The nanocomposites were prepared via a melt-mixing method at various loadings of the synthesized N-MWNTs. The rheological results confirmed that (N-MWNTs)₁₀, at 0.5–2.0 wt.%, did not form any substantial network through the PVDF matrix, thereby exhibiting an electrically insulative behavior, even at a higher concentration of 3.0 wt.%. Although the optical microscopy, TEM, and rheological results confirmed that both (N-MWNTs)₂₀ and (N-MWNTs)₄₀ established a continuous 3D network within the PVDF matrix, (N-MWNTs)₄₀/PVDF nanocomposites exhibited approximately one order of magnitude higher electrical conductivity. The higher electrical conductivity of (N-MWNTs)₄₀/PVDF nanocomposites is attributed to the intrinsic chemical features of (N-MWNTs)₄₀, such as nitrogen content and nitrogen bonding types.

Multilayer polymeric nanocomposites for electromagnetic interference shielding: fabrication, mechanisms, and prospects

Fabrication of multilayer EMI shield opens a creative avenue for designing and constructing flexible nanocomposite films simultaneously featuring excellent EMI shielding performance, fascinating heat removal ability, and robust mechanical properties.