Lightweight and self-healing carbon nanotube/acrylic copolymer foams: Toward the simultaneous enhancement of electromagnetic interference shielding and thermal insulation

Electromagnetic interference (EMI) shielding foams featuring light weight and ultralow thermal conductivity have received attention in a diverse range of applications, but their limited service life makes them very challenging in realistic use. As such, prolonging their service life has aroused significant scientific and technical interest. Herein, we report a facile method to prepare a carbon nanotube/acrylic copolymer (CNT/AC) foam by using isobutane as a blowing agent. This strategy is effective in constructing a 3D porous architecture composed of a segregated CNT network impregnated with an AC polymer through a hot pressing foaming process. This unique structure endows the composite with superior EMI specific shielding effectiveness (for foams with 0.62 vol% CNTs: 1243.3 dB·cm2·g−1) and an extremely low percolation threshold and thermal conductivity (0.008 W·m−1·K−1). More intriguingly, the inherent long-chain entanglements give the foam a self-healing feature. Specifically, with the incorporation of 0.80 vol% CNTs, the healing effectiveness of the EMI shielding performance is greater than 79% in the frequency range from 8.2 GHz to 12.4 GHz. Overall, the resulting CNT/AC foam possesses numerous advantages such as light weight, thermal insulation and EMI shielding self-healing performance, suggesting great potential application value in aviation areas.