Advances in Electromagnetic Interference Shielding Materials with Low Reflection
Li Lang,1 Weining Ren,1 Jingyi Men,1 Xinyuan Mao,1 Zelong Yang,1 Shengrui Zhang1 and Lei Wang1,2,*
1 School of Chemistry and Environment Science, Shaanxi University of Technology, Hanzhong, Shaanxi, 723001, China
2 Shaanxi Key Laboratory of Macromolecular Science and Technology, School of Chemistry and Chemical Engineering, Northwestern Polytechnical University, Xi'an, Shaanxi, 710072, China
*E-mail: mxera@snut.edu.cn; minishiguang@126.com (L. Wang)
With the rapid development of electronic information technology, electromagnetic radiation is ubiquitous in the environment, seriously interfering with the normal operation of other electronic components and human health. However, traditional metal-based electromagnetic interference (EMI) shielding materials usually cause high reflection, resulting in secondary environmental pollution. Therefore, the development of EMI shielding materials with low reflection coefficient (R) and high EMI shielding effectiveness (SE) has received extensive attention from scholars. In this review, the research progress and development trends of low-reflection EMI shielding materials are systematically expounded. Firstly, the shielding mechanism of low-reflection EMI shielding materials is briefly introduced. Then, the preparation methods and structural designs of low-reflection EMI shielding materials are reviewed in detail. Finally, the key scientific and technological problems of low-reflection EMI shielding materials are proposed, and the future development trends are prospected.
Keywords：Electromagnetic interference; Low reflection; Structural designs; EMI shielding composites.
Table of Contents
Innovative Description: This paper systematically expounds the research progress and development trends of low-reflection electromagnetic interference shielding materials.
With the emergence of new-generation information technologies like 5G communication and the Internet of Things, electronic devices are evolving in the directions of higher frequencies, greater power, and higher integration.[1,2] The electromagnetic radiation produced during the operation of these devices not only interferes with the operation of other electronic components but also poses potential hazards to human health.[3,4] The utilization of electromagnetic interference (EMI) shielding materials to block electromagnetic waves (EMWs) is an effective approach to guarantee the normal operation of electronic devices and human health.[5,6] Nevertheless, conventional metal-based EMI shielding materials typically cause high reflection, which is prone to result in severe secondary pollution.[7-9] Hence, the development of EMI shielding materials with low reflection and high absorption characteristics to achieve “green shielding” has become a research focus and an important development trend in the fields of electromagnetic protection.[10-12]
Currently, the research on EMI shielding materials primarily focuses on achieving superior EMI shielding performance through enhancing electrical conductivity (σ).[13-15] However, high σ can lead to impedance mismatch between the service environment and shielding materials. As a result, most of the incident EMWs are reflected from the material surface into the free space with lower impedance, where they continue to propagate.[16-18] This not only complicates the electromagnetic environment but also causes secondary pollution. Therefore, addressing the trade-off between high EMI shielding effectiveness (SE) and low reflection coefficient (R) has emerged as a critical challenge and an important research topic.[19] In recent years, researchers have put forward an “absorption-dominated” EMI shielding mode, which realizes effective dissipation by converting the incident EMWs energy into heat energy and other forms rather than mere reflection.[20-22] To attain this objective, researchers have mainly concentrated on the following aspects: (1) Introducing magnetic components (such as Fe3O4, CoNi, etc.) to establish an electromagnetic synergetic loss network;[23,24] (2) Designing structures with gradient variations in σ/magnetic permeability to optimize impedance matching;[25,26] (3) Developing multi-layer heterogeneous interfaces and porous structures to enhance multiple scattering. These strategies, by regulating the electromagnetic parameters and spatial distribution of shielding materials, maintain high EMI SE while reducing surface reflection.[27] This offers a promising and effective solution to address the inherent trade-off between high EMI SE and low R in the field of EMI shielding.[28]
In the field of EMI shielding, the development of low-reflection EMI shielding materials faces dual challenges from both theoretical and engineering application perspectives. Theoretically, it is necessary to deeply explore the collaborative mechanism of dielectric loss and magnetic loss, and reveal the coupling laws between multi-scale electromagnetic parameters and interface polarization behavior. From the perspective of engineering application, it is essential to solve key issues such as lightweight structural design, wide frequency band, and large-scale production costs. Currently, it is crucial to develop EMI shielding materials with high EMI SE and low R. These materials address the precise electromagnetic protection needs of modern electronic devices and significantly promote advancements in the fields such as 5G communication, aerospace, and intelligent electronics.[29,30]
To address the existing research deficiencies and provide a comprehensive perspective, this review aims to systematically sort out and comment on the key progress and development trends in the field of low-reflection EMI shielding materials in recent years. Firstly, the shielding mechanism of low-reflection EMI shielding materials is briefly introduced. Subsequently, various advanced preparation techniques (such as freeze-drying, 3D printing, electroless plating, etc.) for achieving low-reflection characteristics are comprehensively summarized and compared, along with their advantages and disadvantages. Moreover, the key structural design strategies of low-reflection EMI shielding materials are emphasized and reviewed. Finally, the key scientific and technological problems of low-reflection EMI shielding materials are proposed, and the future development trends are discussed.
2. The low-reflection mechanism of EMI shielding
The shielding effect of materials is measured by SE, which refers to the attenuation of EMI energy within a certain frequency range. SE can be expressed as the logarithm of the ratio of incident power (Pi) to transmitted power (PT), with the unit of dB.[31,32] In that case, SE can be expressed as follows:
(1)
The higher the SE, the stronger the ability of EMI materials to resist microwaves. According to Schelkunoff’s theory, the total EMI shielding effectiveness (SET) can be represented as the sum of absorption loss (SEA), reflection loss (SER), and multiple reflection loss (SEM). The relationship can be described as follows:
(2)
When SET > 15 dB, SEM can be disregarded. SER and SEA can be further expressed as:
(3)
(4)
In the formula, f represents the frequency of the EMWs (Hz); μ is the magnetic permeability of the material (μ = μ0μr, μ0 = 4π×10-7, μ0 is the magnetic permeability of vacuum, μr is the relative magnetic permeability to vacuum (H·m-1); σ is the electrical conductivity of the material (S/m). It indicates that SER is affected by the ratio of σ/μ. Therefore, dielectric materials with extremely high σ and low μ usually exhibit high SER, and SEA is a function of μ and σ, so both SER and SEA increase with the increase of σ.
For low-reflection EMI shielding materials, R and absorption coefficient (A) can directly reflect the proportion of incident EMWs power that is reflected and absorbed. Therefore, by directly comparing the R and A of EMI shielding materials, it is easy to determine the dominant shielding mechanism: if R > A, it indicates that more incident EMWs are reflected and attenuated, with fewer EMWs enter the interior of the material, and thus less EMWs are absorbed and dissipated. That is to say, the shielding mechanism of this material is dominated by the reflection of EMWs. On the contrary, R < A implies that relatively fewer EMWs are reflected on the surface of the material, while more incident EMWs are absorbed and attenuated after enter the interior of the material, signifying that the shielding process of this material is mainly based on absorption.[33]
(5)
When transmission coefficient (T) is sufficiently small, the sum of A and R approaches 1, which indicates that directly comparing A or R with the critical value of 0.5 can also easily determine whether it is a low-reflection EMI shielding material. This judgment method is more applicable under the premise of SET > 20 dB (T < 0.01).
3. Preparation methods of EMI shielding composites with low reflection
Fig. 1: Preparation methods and different structures of low-reflection EMI shielding materials.
Freeze-drying is an advanced preparation method based on the principle of phase change.[34,35] The process involves freezing the water-containing material below the freezing point and then sublimating the ice under high vacuum conditions. The advantages lie in that the dried materials retain the original chemical composition and microstructure, especially the 3D porous network structure resulting during the freezing process.[36,37] The freeze-drying method constructed a composite structure of “porous skeleton-conductive network-heterogeneous interface”. On the one hand, the formed porous structure can significantly extend the propagation path of EMWs, enhance dielectric loss through multiple reflections and scattering, thereby improving EMI SE.[38-40] On the other hand, by inducing interface polarization loss, the dual goals of “low R-high EMI SE” are achieved.
Liu et al.[41] prepared (MXene@Ni/poly(p-phenylene-2,6-benzobisoxazole) nanofibers (PNF)-(MXene/PNF) aerogels through a layer-by-layer freeze-drying technique. When the mass ratio of MXene to Ni in MXene@Ni was 1:6 and the mass fraction of MXene in MXene/PNF was 80 wt%, the EMI SE of (MXene@Ni/PNF)-(MXene/PNF) aerogels achieved 71 dB with R as low as 0.10, realizing absorption-dominated shielding mechanism (Fig. 2(a-f)). Building upon the utilization of freeze-drying for aerogels but exploring a different post-treatment route, Zong et al.[42] fabricated MXene/cellulose nanofibers (CNF) aerogels by freeze-drying method, followed by high-temperature pyrolysis to produce TiC/C aerogels. Due to the porous structure and the abundant heterointerfaces between TiC and CNF, the TiC/C aerogels exhibited excellent EMI shielding performance. Specifically, when the mass fraction of MXene was 3 wt%, the EMI SE of TiC/C aerogels was up to 72.9 dB, and R was 0.24. Ma et al.[43] prepared porous 3D magnetic MXene/Fe3O4@acidified multi-walled carbon nanotubes (MFC) composite aerogels by directional freezing and freeze-drying. When the thickness was 2 mm, the EMI SE of MFC composite aerogels achieved 51.6 dB, and R was 0.31. Shifting the focus towards composite foams, Lei et al.[44] obtained silver fractal dendrites (AgFDs)/carbon nanotubes (CNT)/thermoplastic polyurethane (TPU) composite foams by layer-by-layer assembly combined with freeze-drying technology. When the thickness was 3.4 mm and the loadings of AgFDs was 0.103 vol%, the EMI SE of AgFDs/CNT/TPU composite foams was as high as 88.5 dB, while R was as low as 0.1. In our previous work,[45] Ti3C2Tx@CoNi/Ti3C2Tx/CNF composite foams (TCTCF) with asymmetric structure were prepared by layered freezing and freeze-drying technique. With a mass fraction of 50 wt% for Ti3C2Tx@CoNi, the EMI SE of TCTCF was up to 85 dB, and R was controlled between 0.22 and 0.47 (Fig. 2(g-o)).
Fig. 2: a) Schematic illustration for preparation of (MXene@Ni/PNF)-(MXene/PNF) aerogels. b, c) SEM images of (MXene@Ni/PNF)-(MXene/PNF) aerogels and d) Ni element distribution, e) EMI SE, f) R and A of (MXene@Ni/PNF)-(MXene/PNF) aerogels. Reprinted with permission from Reference [41], Copyright 2024, Wiley-VCH. g) Schematic illustration of fabrication for TCTCF. h, i) SEM images of TCTCF, j, k) Ti3C2Tx/CNF layer and l, m) Ti3C2Tx@CoNi/CNF layers. n) EMI SE and o) R of TCTCF. Reprinted with permission from Reference [45], Copyright 2025, Elsevier.
3.2 Electroless plating method
Electroless plating refers to a coating method in which metal ions are reduced to metals by a reducing agent at room temperature without the application of an external current and deposited on the surface of the substrate. Compared with electroplating, electroless plating technology has the advantages of uniform coating, small pinholes, no need for direct current power supply equipment, and no restrictions on the material and shape of the substrate. By forming functional metal coatings (such as Ni, Cu, Ag) on the surface of non-conductive or weakly conductive substrates through electroless plating, the materials are endowed with excellent σ and magnetic permeability, thereby efficiently achieving reflection and absorption of EMWs.[46,47] Electroless plating, by preparing a highly conductive metal layer, works in concert with gradient conductive structures and porous electromagnetic loss layers to form a “low R-high EMI SE” shielding mechanism, thereby optimizing EMI shielding performance.
Tang et al.[48] prepared Fe3O4/Ag-loaded polyimide (PI) nonwoven fabrics (PFA)/pure Ag-coated PI nonwoven fabrics (PA) composites by in situ growth of Fe3O4 magnetic particles and electroless Ag plating process. When the Ag plating time for PFA and for PA were 1 h and 1.5 h, the EMI SE of PFA/PA composites reached 77 dB, and R was as low as 0.09 (Fig. 3(a-f)). Similarly, Zhao et al.[49] fabricated Fe3O4/Ag/PI (FAP) fabrics by in-situ growing Fe3O4/Ag nanoparticles on the PI surface and performing electroless Ag plating. Finally, the FAP fabrics were assembled with Cu/Ni mesh (CN) to prepare FAP/CN fabrics. Notably, at a thickness of only 430 μm and a low density of 0.37 g/cm3, the EMI SE of FAP/CN fabrics was up to 58 dB in the 24-40 GHz, and R was only 0.26. In a more complex process, Xu et al.[50] deposited nickel-plated aramid paper (NiP) through an electroless Ni plating process, and then fabricated Fe3O4/graphite particles (GP)/polydimethylsiloxane (PDMS) impregnated and polymerized polypyrrole (PPy) coated melamine foam layer (PGF-FL-NiP) composites. With a thickness of 2 mm, the EMI SE and R of PGF-FL-NiP composites were 62 dB and 0.23, respectively (Fig. 3 (g-i)).
Fig. 3: a) Schematic illustration of preparation process of PFA/PA composites. SEM images of b) PA, c, d) PFA, e) EMI SE and f) R of PFA/PA composites. Reprinted with permission from Reference [48], Copyright 2024, Springer. g) Schematic diagram of the preparation process of PGF-FL-NiP composites. h) EMI SE, i) R and A of PGF-FL-NiP composites. Reprinted with permission from Reference [50], Copyright 2024, American Chemical Society.
3.3. Vacuum-assisted filtration method
Vacuum-assisted filtration applies negative pressure on hydrophilic microporous filter membranes.[51,52] The process removes solvents from the mixed solution of conductive fillers and polymer matrices through a pressure difference. This process can precisely control the microstructure of EMI shielding materials with excellent interface interaction to achieve high performance.[53] The core of vacuum-assisted filtration technology lies in precisely constructing an electromagnetic gradient structure. Through layered design, impedance matching is optimized (to reduce reflection), and the “absorption-reflection-reabsorption” mechanism and interface polarization loss (to enhance absorption) are utilized. Ultimately, the shielding requirement of “dominant absorption” is met.
Guo et al.[54] fabricated CoFe2O4@MXene-silver nanowires (AgNWs)/CNF composite films via vacuum-assisted filtration technology. With a thickness of 0.1 mm, the EMI SE of CoFe2O4@MXene-AgNWs/CNF composite films was up to 84.3 dB, and R was 0.42 (Fig. 4 (a-g)). Similarly, Kim et al.[55] fabricated MXene/polyvinyl alcohol (PVA)/polyacrylic acid (PAA)-Hanji (MPP-H) textiles via vacuum-assisted filtration technology. When the MPP content was 2.77 mg cm-2, the EMI SE of MPP-H textiles was 42 dB, and R was 0.45 (Fig. 4 (h-k)). In terms of structural design and performance optimization, Ma et al.[56] employed a layer-by-layer vacuum-assisted filtration to fabricate MXene/FeCo/CNF composite films with controllable magnetic-conductive dual-gradient structure. With a thickness of 340 μm, the EMI SE of MXene/FeCo/CNF composite films reached 58 dB, and R was 0.61. Furthermore, Li et al.[57] utilized vacuum-assisted filtration technology to prepare carbon fibers (CF)@NiCo/PI films. When the thickness was 1.08 mm, the EMI SE of CF@NiCo/PI films was as high as 87 dB, and R was as low as 0.13.
Fig. 4: a) Schematic illustration of fabrication process of CoFe2O4@MXene hybrids and b) CoFe2O4@MXene-AgNWs/CNF composite films. SEM images of c) CoFe2O4@MXene-AgNWs composite films d, e) CoFe2O4@MXene-CNF layer. f) EMI SE and g) R of CoFe2O4@MXene-AgNWs/CNF composite films. Reprinted with permission from Ref. [54], Copyright 2023, Elsevier. h) Preparation of MPP-H textiles. i) SEM images, j) T, R, A and k) EMI SE of MPP-H textiles. Reprinted with permission from Ref. [55], Copyright 2024, Wiley-VCH.
3.4 3D printing method
3D printing technology, based on digital models, can customize the shape of polymer materials according to a certain layer thickness and predetermined stacking trajectory.[58,59] With 3D printing technology, it is expected to prepare conductive composites with excellent performance and designable shapes, meeting the EMI shielding application requirements in different scenarios.[60-62] 3D printing achieves the “low reflection-multiple absorption and dissipation” mechanism of EMWs by precisely designing gradient structures, constructing hierarchical porous networks and regulating the synergistic effects of materials, providing a new approach for the preparation of absorption-dominated EMI shielding materials.
Xue et al.[63] utilized 3D printing technology to continuously print MXene/CNT/ PAA composite inks with different CNT contents, and then prepared gradient-conductive MXene/CNT/PI (GCMCP) composite aerogels through freeze-drying and thermal imidization treatment. With a thickness of 5 mm, the GCMCP aerogels demonstrated excellent EMI SE up to 68.2 dB and an ultra-low R of 0.23 (Fig. 5 (a-f)). Besides, Hou et al.[64] obtained a polylactic acid (PLA)@MWCNT/PDMS@carbonyl iron powder (CIP) composites with a ring-shaped electromagnetic synergistic structure by 3D printing and solution casting techniques. When the thickness was 0.4 mm, the EMI SE of PLA@MWCNT/PDMS@CIP composites was 31 dB, and R was 0.3 (Fig. 5 (g-j)). On the exploration path of structural innovation and performance improvement, Zhang et al.[65] fabricated lattice-filler dual-gradient Fe3O4/CNT/polyurethane (PU)@MXene (DGFCP@M) composite frames by 3D printing technology. The DGFCP@M composite frames displayed an outstanding EMI SE of 72 dB and R as low as 0.38.
Fig. 5: a) Schematic illustration of fabrication process of the GCMCP aerogel frames. b, c) SEM images and d) TEM images of GCMCP aerogels. e) EMI SE and f) A of GCMCP aerogel frames with different lattice sizes. Reprinted with permission from Reference [63], Copyright 2023, Springer. g) Preparation of PLA@MWCNT filaments and the 3D-printed frameworks. h) Schematic diagram of incoming EMWs from different directions, i) EMI SE and j) A of PLA@MWCNT/PDMS@CIP composites. Reprinted with permission from Reference [64], Copyright 2024, Elsevier.
3.5 Electrospinning method
Electrospinning is a nanofiber preparation method based on the induction of an electric field. Its fundamental principle involves utilizing a high-voltage electrostatic field to induce charged jets from polymer solutions or melts, which subsequently solidify into fibers.[66-68] Nanofibers prepared by electrospinning have characteristics such as high aspect ratio, controllable porosity, and excellent mechanical properties. Electrospinning technology provides key support for EMI shielding materials to balance impedance matching and enhance EMWs absorption by constructing a multi-level structure of “continuous fiber network-porous morphology”. Through the design of nanofiber structures and the combination of functional components, it has broken through the limitations of traditional EMI shielding materials, which are “thick, brittle, and narrow-band,” and has shown significant value in the field of EMI shielding.[69,70]
Chen et al.[71] fabricated core-shell structured CP@PANI aerogels by freeze-drying and in situ growth of polyaniline (PANI) to coat carbon nanofibers (CNFs). When the thickness was 3 mm, the CP@PANI aerogels exhibited a remarkable EMI SE of 85.4 dB, corresponding to a low R of 0.43 (Fig. 6(a-d)). In contrast, focusing on stimuli-responsive materials, Tang et al.[72] used electrospinning technology with PAA as the precursor to in-situ introduce thermally expandable microspheres (EM), CNT and iron flakes (ZAF-5) into PI nonwoven fabrics (PMCZ). Finally, the PMCZ/liquid metal (LM) nonwoven fabrics were fabricated through chemical imidization, single-sided alkali treatment, and LM spraying process. Under a thermal stimulus of 170oC, the EMI SE of PMCZ/LM nonwoven fabrics was 57.5 dB, and R was 0.24. Meanwhile, utilizing waste materials, Gao et al.[73] prepared hydrolysate of waste leather scraps (HWLS)/polyacrylonitrile (PAN)/zeolitic imidazolate framework-67 (ZIF-67) nanofiber films through electrospinning technology. Finally, the Co@CNF@perfluorooctyltriethoxysilane (POTS) nanofiber films were successfully prepared by pre-oxidation, carbonization treatments and coating a POTS layer. With a thickness of 250 μm, the Co@CNF@POTS composite films exhibited an EMI SE of 49 dB and a low R of 0.43. Zhang et al.[74] prepared polydopamine (PDA)/silver nanoparticles (AgNPs)/MWCNT/Fe3O4 hybrid fillers (MFs) (TAMF) films via electrospinning technology. When the spray-coating times of PDMS/MFs was 3, the EMI SE of TAMF films was up to 85.4 dB, and R was 0.61 (Fig. 6(e-k)).
Fig. 6: a) Fabrication process of BBB nanofiber and b) CP@PANI aerogels, c) EMI SE and d) SER, SEA, SET of CP@PANI aerogels. Reprinted with permission from Reference [71], Copyright 2025, Springer. e) Schematic diagram of the preparation process of TAMF films. f-i) SEM images of TAMF films. j) EMI SE, k) A and R of TAMF films. Reprinted with permission from Reference [74], Copyright 2022, ACS.
4. Structural design of low reflection EMI shielding materials
The key to the design of low-reflection EMI shielding materials lies in the coordinated optimization of structural regulation and loss mechanism, so as to achieve efficient EMWs absorption and impedance matching. Based on the microstructure, the structural design of low reflection EMI shielding materials can be classified into three ways: 1) porous structures; 2) multi-layer structures and 3) asymmetric/gradient structures.
4.1 Low reflection EMI shielding materials with porous structure
The porous structure design can effectively construct 3D conductive and magnetic flux pathways with low filler content.[75] Through the reasonable regulation of the conductive network and the porous structure, EMWs are reflected multiple times within shielding materials and transformed into heat energy for dissipation, thereby enhancing the absorption loss.[76, 77] At the same time, it effectively reduces surface reflection, thereby achieving absorption-dominated EMI shielding performance.[78-80]
Chu et al.[81] fabricated a honeycomb-structured porous Fe3O4@PPy/PI composite foams by using chemical foaming and in-situ vapor deposition of PPy technology. Due to the 3D porous structure of PI foams and the excellent σ of PPy films, with only 20 wt% Fe3O4@PPy, the EMI SE of Fe3O4@PPy/PI composite foams was 41.1 dB, and R was 0.62. In contrast, aiming for both higher EMI SE and lower R, Zhu et al.[82] fabricated Fe3O4@CNT/MXene/cross-linked aramid nanofiber (c-ANF)/PI (FMAP) aerogels with a 3D ordered hierarchical porous structure by using the unidirectional freezing strategy. With a mass fraction of 8 wt% for both Fe3O4@CNT and MXene, the FMAP aerogels achieved an excellent EMI SE of 67 dB and a low R of 0.14. Wang et al.[83] demonstrated an effective densification strategy to construct a compact porous structure of carbon black/graphene/Ni PI foams (CGNPF). With a thickness of 2 mm, the EMI SE of CGNPF was 44 dB, and R was as low as 0.29 (Fig. 7 (a-g)). Building upon porous structure design but achieving significantly higher EMI SE across a broad frequency range, Mao et al.[84] adopted ice crystal dissolution/regeneration and atmospheric pressure drying strategy to prepare a cellulose-based composite aerogels (CNA) with discontinuous pores structures through layer-by-layer freeze casting. The CNA achieved an ultra-high EMI SE exceeding 90 dB and an ultra-low R of 0.2 across a wide band (1-18 GHz) (Fig. 7 (h-l)). Wei et al.[85] constructed natural rubber (NR)/Fe3O4@CNT/expandable polymer microsphere (EPM) (NMCE) foam via latex mixing followed by template method. With a thickness of 2 mm, the NMCE foams achieved EMI SE of 30 dB and R of 0.28. Further exploring the versatility of freeze-drying for creating porous architectures, Ghosh et al.[86] prepared P-doped MXene/poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) (MXP@PP) aerogels with a porous structure by freeze-drying process. With a mass fraction of MXP at 10 wt%, the EMI SE and R of MXP@PP aerogels were 40 dB and 0.4, respectively.
The core advantage of the porous structure design lies in its excellent impedance matching and enhanced internal loss mechanism, while also offering benefits such as lightweight and potential breathability. However, its inherent limitation is weak mechanical strength. The current main challenges are focused on accurate and efficient theoretical modeling, optimization of wideband strong absorption, improvement of low-frequency performance, and cost control and large-scale production.
Fig. 7: a) Schematic diagram of preparation process of CGNPF and b) the cells of the “collapse densification” process. c, d) SEM images and e) C, O, Ni element distribution of CGNPF. f) EMI SE and g) A of CGNPF. Reprinted with permission from Reference [83], Copyright 2025, Elsevier. h) Preparation process illustrations and performance demonstration of the CNA. i) Ice crystal dissolution/regeneration strategy for the design of discontinuous pore gradients. j) The ultra-low reflection mechanism of CNA. k) EMI SE, l) A, R, and T of CNA. Reprinted with permission from Reference [84], Copyright 2025, Wiley-VCH.
4.2 Low reflection EMI shielding materials with multi-layer structure
In the field of EMI shielding, multi-layer structure is an effective strategy to optimize EMI shielding performance.[87] Through reasonable design and integration of different functional layers, this multi-layer structure can not only achieve superior EMI SE, but also endow shielding materials with multifunctional properties such as thermal management, corrosion resistance, and stretchability, demonstrating broad application prospects.[88]
Chen et al.[89] fabricated reduced graphene oxide@fabric/graphene films (rGO@F/GF) by an evaporation-induced self-assembly strategy in combination with a centrifugal-assisted dip-coating method. At a thickness of less than 0.8 mm, the EMI SE of rGO@F/GF achieved 80 dB, and R was 0.172. In contrast, pursuing similar goals but through a divergent material system and approach, Mai et al.[90] prepared magnetic zeolitic imidazolate frameworks (ZIFs)-derived hollow CoNi carbon nanocage/MXene/nanocellulose bilayer (BZMN) aerogels by a two-step freezing method. When the mass fraction of MXene was 75 wt%, the EMI SE of BZMN aerogels was 35 dB, and R was 0.28 (Fig. 8 (a-g)). Similarly exploring composite films but employing different techniques, Cheng et al.[91] fabricated sandwich-structured polyacrylate (PEA) composite films by spray coating and layer-by-layer casting (LBL-casting) techniques. With a mass fraction of 6 wt% for Fe3O4, the EMI SE of Fe3O4/MWCNT/Fe3O4 composite films reached 38.2 dB, and R was 0.44. Xu et al.[92] fabricated CF/graphene fibers (GF)/PDMS composite films with a double-layer conductive network structure by using solution casting techniques. When the mass fraction of CF and GF were 0.01 wt% and 1.00 wt%, the EMI SE of CF/GF/PDMS composite films reached 34 dB, and R was as low as 0.018. Shifting focus towards achieving exceptionally low reflection, Chang et al.[93] fabricated Fe3O4 decorated aramid fiber (AF)/CNT modified ultra-high molecular weight polyethylene (UHMWPE) fiber/CF (Fe3O4@AF/CNT@UF/CF)/epoxy composites by using a progressive conductive modular assembly strategy. When the number of layers of Fe3O4@AF, CNT@UF and CF fabrics were 4, 6 and 4 respectively. The EMI SE of Fe3O4@AF/CNT@UF/CF composites achieved 78.6 dB, and R was as low as 0.05 (Fig. 8 (h-q)). Further advancing the design of high-performance and flexible EMI shielding textiles, Chen et al.[94] fabricated multifunctional flexible multilayered AgNPs/AgNWs/MXene/FeCo-C (AgDMC) textiles by using a noval multilayer self-assembly strategy. After being immersed in MXene and FeCo-C suspensions, the AgDMC textiles exhibited excellent EMI SE of 88 dB, with R as low as 0.168. This work provided a new strategy for low-reflection and absorption-dominant EMI shielding materials.
The multi-layer structure, with its advantages of wideband impedance matching, functional layer synergy, and low-frequency performance improvement, has demonstrated its value in flexible electronics, military stealth, and EMI shielding of precision equipment through the “surface impedance matching-internal strong attenuation” and “conductive-magnetic-conductive” layering design. However, it has limitations such as large thickness and weight, interface issues, and complex processes. Currently, it is necessary to overcome challenges such as ultra-thinness, material integration, and interface control, and promote its application in high-end electronics and national defense fields through material modification and intelligent design.
Fig. 8: a) Schematic diagrams of the preparation of BZMN aerogels. SEM images of the b) pore structure, c) lower layers, and d) upper layers of BZMN aerogels. e) EMI SE, f, g) T, A and R of BZMN aerogels. Reprinted with permission from Reference [90], Copyright 2024, Wiley-VCH. h) Fe3O4@AF fabrics prepared by in-situ growth method. i) CNT@UF fabrics prepared by spraying method. j) Treatment of woven CF. k-m) SEM images of the CNT@UF fabrics. n) EMI SE, o) R and p) A of the Fe3O4@AF/CNT@UF/CF composites. q) Schematic of the shielding mechanism for Fe3O4@AF/CNT@UF/CF composites. Reprinted with permission from Reference [93], Copyright 2023, Elsevier.
4.3 Low reflection EMI shielding materials with asymmetric/gradient structure
Asymmetric/gradient structure refers to the structure in which the conductivity of each layer varies irregularly or increases gradually along the direction of EMWs incidence. The main factors affecting the EMI SE of asymmetric/gradient structure are the σ of the conductive layer, absorbing layers and the direction of EMWs incidence.[95-97] The asymmetric/gradient conductive structure forms an absorption-reflection-reabsorption interface for EMWs, endowing the material with excellent EMI shielding performance dominated by absorption.[98,99]
Qian et al.[100] fabricated TPU/CNT/Fe3O4-decorated rGO/Ag composite foams (TCFAs) with an asymmetric structure by a supercritical CO₂ foaming process and thermal stretching. With a filler content as low as 1.784 vol%, the EMI SE of TCFAs was up to 89.5 dB, and R as low as 0.253. Similarly focused on achieving high EMI SE with low R through structural design, He et al.[101] integrated MXene and liquid metal nanoparticles (LMNPs) into a dual-network structure composed of PVA and CNF. By taking advantage of gravity-induced natural sedimentation of LMNPs. Finally, the asymmetric gradient-structured PVA/CNF/MXene/LM (APCML) aerogels were prepared. When the thickness was 3 mm, the EMI SE of APCML aerogels achieved 71 dB with R only 0.064, demonstrating a compatible balance between shielding and microwave absorption performance (Fig. 9 (a-f)). In a different approach utilizing hybrid fillers and surface modification, Zhang et al.[102] ultrasonically adsorbed the hybrid filler of MWCNT and Fe3O4 (MFs) onto the surface of TPU fibers and then attached a layer of AgNWs to the TPU/Fe3O4@MWCNT fiber films using vacuum-assisted filtration technology. Finally, the TPU/MFs/AgNWs (TMA) composite films were prepared. When the amount of AgNWs was 2.7 wt% and the thickness was 78 μm, the EMI SE of TMA composite films reached as high as 78.48 dB, and R was 0.56. (Fig. 9 (g-l)). Further exploring asymmetric structures but employing directional freezing, Yao et al.[103] obtained MXene/ANF/PI (AMAP) aerogels with an asymmetric structure through vacuum-assisted filtration technology and directional freezing casting process. Under the interaction of the layered MXene/ANF and porous AMAP structures, when the thickness was 15 mm, the EMI SE of AMAP aerogels was 47 dB, corresponding to a low R of 0.0138.
Gradient structures can achieve efficient broadband EMWs absorption at relatively thin thicknesses, but they still face challenges such as difficult interface bonding and theoretical model construction. Asymmetric structures can realize low reflection characteristics on one side of the material and integrate other functions (such as thermal conduction, magnetism, etc.) on the other side, making them suitable for directional electromagnetic control or thermal management scenarios. However, when designing, the mutual influence of the performance on both sides needs to be taken into account, and higher requirements are placed on the interface bonding strength and material compatibility. These two structures still face challenges in terms of preparation processes, performance stability, etc., and their commercialization needs to be promoted through material innovation, process optimization and theoretical improvement.
 |
Fig. 9: a) Schematic illustration of preparation process of APCML. b-d) SEM images of APCML aerogels. e) EMI SE, and f) power coefficient of APCML aerogels. Reprinted with permission from Reference [101], Copyright 2024, Wiley-VCH. g) Schematic illustration for fabrication procedure of TMA composite films. h-j) SEM images of TMA composite films. k) EMI SE of TMA composite films. l) EMI SE vs R and EMI SE vs thermal conductivity (TC) comparisons of TMA composite films with different polymer composites reported in previous work. Reprinted with permission from Reference [102], Copyright 2023, Elsevier.
Table 1 presents a comparative analysis of the EMI SE and R of different types of low-reflection EMI shielding materials. The table selects representative conductive polymer-based composites, metal-based composites, carbon-based composites, and novel nano-composite shielding materials from current research as the research objects.
Table 1: Comparison for EMI shielding performance and R of low-reflection EMI shielding materials.
|
Thickness (mm) |
EMI SE (dB) |
R |
Reference |
|
|
MXene/Fe3O4@aMWCNT |
2 |
51.6 |
0.31 |
[44] |
|
PI/Fe3O4/Ag/Cu/Ni |
0.43 |
58 |
0.26 |
[49] |
|
CoFe2O4@MXene-AgNWs/CNF MXene/FeCo/CNF CF@NiCo/PI MXene/CNT/PI |
0.1 0.34 1.08 5 |
84.3 58 87 68.2 |
0.42 0.61 0.13 0.23 |
[54]
[56]
[57]
[63] |
|
PLA@MWCNT/PDMS@CIP |
0.4 |
31 |
0.3 |
[64] |
|
Co@CNF@POTS Fe3O4@PPy/PI |
0.25 8 |
49 41.1 |
0.43 0.8 |
[73]
[81] |
|
Carbon/graphene/Ni PI PVA/CNF/MXene/LM TPU/MFs/AgNWs |
2 3 0.078 |
44 71 78.4 |
0.29 0.064 0.56 |
[83]
[101]
[102] |
|
MXene/ANF/PI |
15 |
47 |
0.013 |
[103] |
|
PVDF/SiCNW@MXene/PVDF/CNT LM-coated textile |
3.8 1 |
45 49 |
0.03 0.4 |
[104]
[105] |
|
LM/elastomeric polymer Waterborne polyurethane foam Ni/MXene/melamine foam |
2 4 2 |
66 84 34.6 |
0.5 0.08 0.16 |
[106]
[107]
[108] |
Therefore, exploring and developing new preparation and processing methods, simplifying the process, adjusting the product size, and reducing production costs are crucial for the development of low-reflection EMI shielding materials. To achieve EMI shielding materials with both high EMI SE and low R, the materials need to optimize the multiple loss paths of EMWs through structural design while reducing surface reflection. The design of porous structures can increase the scattering and interface polarization losses of EMWs, while reducing direct surface reflection. Although the introduction of porous structures can improve impedance matching (reduce surface reflection), excessive pursuit of low reflection may sacrifice overall EMI SE. Multilayer structures reduce the reflection of incident waves by alternately stacking functional layers with different electromagnetic properties and utilizing the impedance gradient matching between layers, while promoting multiple scattering and absorption of EMWs. However, the polymer matrix is separated by selectively distributed conductive fillers, which can lead to a decrease in the mechanical properties. Gradient/asymmetric structures achieve gradual impedance matching through continuous gradient changes in composition or porosity (such as increasing the concentration of conductive fillers along the thickness direction), allowing EMWs to gradually enter the shielding material and be absorbed rather than directly reflected. In the design of gradient/asymmetric structures, the thickness, component ratio, and porosity of the gradient layers need to be precisely matched. Otherwise, impedance matching may fail. Therefore, for the preparation of EMI shielding materials with both high EMI SE and low R, reasonable and efficient structural design is of vital importance.
Based on this, advanced preparation and processing methods (such as chemical vapor deposition (CVD) and microfluidic technology) should be developed, along with precise design for microstructure optimization based on low-reflection EMI shielding materials to achieve the collaborative optimization of various physicochemical properties of EMI shielding materials. At the same time, multiple preparation methods should be combined, such as 3D printing in conjunction with ice templating to prepare gradient porous-dense materials, further improving EMI SE. In addition, the relationship between shielding materials and EMWs should be explored to enhance understanding of the intrinsic EMI shielding mechanisms, which will greatly promote the development of the next generation of low-reflection EMI shielding materials.
In conclusion, the key to the development of low-reflection EMI shielding materials lies in innovative breakthroughs in preparation methods and precise control of microstructure, which is essential for driving them from laboratory research to industrial application. It is believed that low-reflection EMI shielding materials will evolve towards intelligence, sustainability, and multifunctionality. This new type of materials will play a crucial role in fields such as electronic communication, flexible wearable devices, and aerospace in the future.
Acknowledgment
This work was supported by the National Natural Science Foundation of China (52303090); The Innovation Capability Support Plan of Shaanxi Province (2024ZC-KJXX-022); The Youth Talent Promotion Project of Shaanxi Science and Technology Association (20240426); The Youth Innovative Team of Shaanxi Universities (No.2022.94).
Conflict of Interest
There is no conflict of interest.
Reference
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