Optimization of mechanical and electromagnetic interference shielding properties of expanded graphite/polyurethane composite foams

The expanded graphite (EG) was used as a filler in EG/polyurethane (PU) composite foams for electromagnetic interference shielding (EMI). The EG/PU composite foams were characterized by Fourier transform infrared spectroscopy (FTIR) and SEM. The shielding effectiveness (SE) of the EG/PU composite form containing 5 wt% EG was −24 dB at 5 wt% in the 8–12 GHz range. The optimal EG loading was 3 wt% and the corresponding EG/PU composite foam had a total SE of −18.9 dB and fairly good mechanical characteristics (compressive strength: 13.43 MPa and compressive modulus: 4.95 MPa). These attributes position the EG/PU composite foam as a promising candidate for diverse EMI SE applications. Highlights Synthesis by thermal exfoliation and characterization by x‐ray diffraction, Raman and SEM of EG. Preparation of EG/PU foams for enhanced EMI SE. Optimization of the EG loading with regard to SE and mechanical properties of the EG/PU foams. Optimization amongSE, EG loading and mechanical properties for EG/PU composite foams.