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Abstract <p>The growing demand for lightweight, flexible, and thermally conductive materials for electromagnetic interference (EMI) shielding is driven by the rapid miniaturization and compact integration of electronic devices. In this study, we report thermoplastic elastomer nanocomposite foams based on ethylene-octene copolymer (EOC), reinforced with a hybrid filler comprising reduced graphene oxide (RGO) and multiwalled carbon nanotubes (MWCNTs). A combined melt–solution mixing method followed by chemical foaming was employed to fabricate microcellular structures with well-dispersed 1D–2D carbon nanomaterials. The synergistic interaction between RGO and MWCNTs resulted in a highly interconnected 3D conductive network at a low percolation threshold of 3&#xa0;wt.%. This architecture enabled absorption-dominated EMI shielding with an effectiveness of 26.5&#xa0;dB (specific shielding effectiveness of (220&#xa0;dB.cm<sup>2</sup>/gm) and an absorption coefficient of 88% at 10&#xa0;wt.% loading in the X-band (8.2–12.4&#xa0;GHz). The presence of thicker interwall and uniformly distributed hybrid fillers also enhanced thermal conductivity by approximately 65% (reaching 0.278&#xa0;W&#xa0;m<sup>−1</sup>&#xa0;K<sup>−1</sup>), while maintaining low density and good mechanical resilience. These multifunctional nanocomposite foams demonstrate strong potential for EMI shielding and thermal management in compact, high-performance electronic systems.</p> Graphical Abstract <p></p>

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Thermoplastic elastomer nanocomposite foams with 3D carbon hybrids for electromagnetic radiation suppression with heat absorption

  • 期刊论文

  • 发表日期：

    2025年11月24日

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  • Jasomati Nayak,
  • Aparajita Pal,
  • Sreeja Nath Chowdhury,
  • Shovan Biswas,
  • Palash Das,
  • Soumen Giri,
  • Pallab Banerji,
  • Narayan Ch. Das

摘要

Abstract

The growing demand for lightweight, flexible, and thermally conductive materials for electromagnetic interference (EMI) shielding is driven by the rapid miniaturization and compact integration of electronic devices. In this study, we report thermoplastic elastomer nanocomposite foams based on ethylene-octene copolymer (EOC), reinforced with a hybrid filler comprising reduced graphene oxide (RGO) and multiwalled carbon nanotubes (MWCNTs). A combined melt–solution mixing method followed by chemical foaming was employed to fabricate microcellular structures with well-dispersed 1D–2D carbon nanomaterials. The synergistic interaction between RGO and MWCNTs resulted in a highly interconnected 3D conductive network at a low percolation threshold of 3 wt.%. This architecture enabled absorption-dominated EMI shielding with an effectiveness of 26.5 dB (specific shielding effectiveness of (220 dB.cm2/gm) and an absorption coefficient of 88% at 10 wt.% loading in the X-band (8.2–12.4 GHz). The presence of thicker interwall and uniformly distributed hybrid fillers also enhanced thermal conductivity by approximately 65% (reaching 0.278 W m−1 K−1), while maintaining low density and good mechanical resilience. These multifunctional nanocomposite foams demonstrate strong potential for EMI shielding and thermal management in compact, high-performance electronic systems.

Graphical Abstract