Optimizing PANI/Epoxy Polymer Blends for Enhanced EMI Shielding Performance

The development of flexible epoxy/polyaniline (PANI) composite films for electromagnetic interference (EMI) shielding applications is presented in this work. Using a solution casting technique, the composites were created with PANI loadings ranging from 0 to 20 weight percent. Fourier transform infrared spectroscopy (FTIR) and X‐ray photoelectron spectroscopy (XPS) were used to examine the films’ structural and chemical properties, verifying that PANI had been successfully incorporated into the epoxy matrix. Field emission scanning electron microscopy (FESEM) was used to analyze morphological aspects, which showed how filler dispersion and network development changed as PANI concentration increased. The X‐band frequency range (8–12 GHz) was used to assess the composites’ EMI shielding effectiveness. The development of conductive channels inside the insulating epoxy matrix is responsible for the results, which demonstrate a gradual improvement in shielding efficacy with increasing PANI concentration. A maximum shielding efficiency of around 20 dB, or almost 99% attenuation of incoming electromagnetic waves, was demonstrated by the optimized composite with 15 weight percent PANI. Only a slight improvement was seen above this concentration, signifying the beginning of percolation threshold saturation. These results show that epoxy/PANI composites provide a promising blend of lightweight properties, flexibility, and efficient EMI shielding.