Lightweight, flexible, highly efficient and highly stable multifunctional electromagnetic shielding materials are in high demand in both civilian and military fields. In this paper, a flexible conductive foam SFPU/Fe3+-CNTs was prepared by co-foaming using solvent-free polyurethane (SFPU) as the matrix and ferric chloride (FeCl3) and carbon nanotubes (CNTs) as fillers, taking advantage of the rapid polymerization and chemical foaming mechanism of SFPU. Then, a lightweight and compressible CNTs@SFPU/Fe3+-CNTs electromagnetic shielding foam was fabricated by ultrasonic-assisted impregnation of CNTs. The composition, microstructure and electromagnetic shielding performance of the flexible conductive foam were analyzed by FT-IR, XRD, SEM and vector network analyzer, and the mechanism of the synergistic enhancement of electromagnetic shielding performance by FeCl3 and CNTs was explored. Thanks to the unique porous structure for dissipating electromagnetic waves and the synergistic shielding effect of FeCl3 and CNTs, the foam exhibited a high electromagnetic interference shielding performance of 52 dB in the X-band and a high specific shielding effectiveness of 595.4 dB/(g/cm3) at a thickness of 3 mm. Moreover, the foam maintained its efficient electromagnetic shielding performance after compression cycles, water washing and tape peeling. Finally, the thermal insulation and flame retardant properties of the conductive foam were investigated, greatly expanding its practical application scenarios. This work presents a simple and scalable method for fabricating lightweight and efficient electromagnetic shielding materials for applications in civil, aerospace, military, and other fields.
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