Preparation of flexible EPDM rubber nanocomposites with enhanced electromagnetic shielding by combining pyrrole-modified MXene and copper nanowires

Abstract Overcoming the trade-off between electromagnetic interference (EMI) shielding and mechanical flexibility remains a critical challenge for advanced electronics. Herein, we design flexible ethylene propylene diene monomer (EPDM) nanocomposites incorporating one-dimensional copper nanowires (CuNWs) and two-dimensional pyrrole-modified MXene (PPy-MXene). The PPy modification significantly improves the dispersion and interfacial compatibility of MXene within the rubber matrix, while the high-aspect-ratio CuNWs synergistically construct an efficient 1D/2D interpenetrating conductive network with PPy-MXene at an ultralow total filler loading of only 6 wt%. Benefiting from this structural synergy, the composite achieves an outstanding balance of EMI shielding, conductivity, and mechanical robustness. Specifically, the composite filled with 1 wt% PPy-MXene and 5 wt% CuNWs exhibits a practical EMI shielding effectiveness of 28.35 dB in the X-band, satisfying the commercial requirement (>20 dB) and outperforming single-filler systems at the same total loading. Remarkably, the composite retains exceptional elastomeric characteristics with a tensile strength of ∼14 MPa and an elongation at break exceeding 600%. This work provides an effective strategy to circumvent the typical electrical-mechanical trade-off in elastomers, paving the way for flexible EMI shielding applications.