Fabrication of highly flexible electromagnetic interference shielding polyimide carbon black composite using hot-pressing method

Traditionally, electromagnetic interference (EMI) shielding material has been occupied by metallic materials due to its high electric conductivity and EMI shielding effect. However, with rising demands from technology development for light-weight, highly durable, and easily moldable materials, metallic materials are gradually being substituted by polymer composite materials. Still, there are limitations on polymer composite as EMI shields: High ratio of fillers in composite achieves excellent EMI shielding effect but it severely compromises its mechanical behaviors. In many studies, they have failed to fabricate the high-ratio filler films with good mechanical durability, but here the initially fragile high-ratio film has been transformed to a flexible film by a very simple method: Hot-pressing. This approach not only solved the problems mentioned above but further provided a possible breakthrough point for composite study by solving threshold of the maximum loading of the fillers in polymer matrix. The stiff composite of polyimide sponge with exceeding carbon black loading became a highly flexible EMI SE film with doubled tensile strength and enhanced EMI SE. As a result, a new way of fabricating flexible EMI shielding polymer composite is demonstrated with great potential applications in aerospace and wireless communications.