Large‐Scale Ultralight and Flexible Metal Foil/Polymer Sandwich Composites with Excellent Electromagnetic Interference Shielding

Abstract Metal materials play an important role in electromagnetic interference (EMI) shielding due to their ultra‐high electrical conductivity, but they are rigid and inflexible, as well as of high density, which limits their application in some areas. In this study, a novel and simple method to fabricate the composites of metal foil and polymer is reported. A copper foil (Cuf) with micropores on the surface is used as a shielding matrix, then interpenetrating and interlocking nanostructure as well as reactive groups are introduced on its surface, and then silicone rubber (SiR) is coated on both surfaces to form a sandwich structure, and the obtained Cuf/SiR composites possesses high EMI shielding efficiency (SE), strong interface adhesion, and low density. The average EMI shielding efficiency of the obtained Cuf/SiR composites in the range of 1.13–18 GHz is 111.5 dB, with a high interface adhesion strength of 5.2 N cm −1 and low density of 1.3 g cm −3 , and it also possesses bending and splicing properties, which exhibits broad potential application in the field of EMI shielding tents and shielding rooms. This preparation method of the composites is simple and efficient, and provides a guideline for the design and fabrication of metal foil/polymer composites in molding method.