Flexible waterborne polyurethane (WPU)/silver nanowire (AgNW) nanocomposites with unidirectionally aligned micrometer-sized pores are fabricated using a facile freeze-drying process, and their dimensions, densities, and AgNW contents are easily controllable. The high-aspect-ratio AgNWs are well-dispersed in the nanocomposite cell walls, giving the nanocomposites good compression strength and excellent electrical conductivity even at very low densities. The large conductivity mismatch between the AgNWs and WPU also induces substantial interfacial polarization that benefits the absorption of electromagnetic (EM) waves, whereas the aligned cell walls promote multireflections of the waves in the porous architectures, further facilitating the absorption. The synergistic actions of the AgNWs, WPU, and unidirectionally aligned pores lead to ultrahigh EM shielding performance. The X-band shielding effectiveness (SE) of the nanocomposites is 64 and 20 dB at the densities of merely 45 and 8 mg/cm, respectively, and ultrahigh surface specific SE of ∼1087 dB cm/(g mm) is achieved with only 0.027 vol % AgNWs, demonstrating that they are promising ultralight, flexible, mechanically robust, high-performance EM shielding materials.

Ultralight and highly elastic reduced graphene oxide (RGO)/lignin-derived carbon (LDC) composite aerogels with aligned micron-sized pores and cell walls are prepared using a facile freeze-drying method. The presence of a small fraction of LDC in the cell walls enhances the interfacial polarization effect while almost maintaining the amount of charge carriers and conductivity of the cell walls, greatly boosting the wave absorption capability of the cell walls. RGO/LDC aerogels also show a greater number of large cell walls with better integrity than RGO aerogels, further improving the multiple reflection ability of the aligned cell walls. Synergistic effects of the multiphase cell walls and the preferred microstructures of the RGO/LDC aerogels lead to their high electromagnetic interference (EMI) shielding effectiveness of 21.3-49.2 dB at an ultralow density of 2.0-8.0 mg/cm. This corresponds to the surface-specific SE (SE divided by density and thickness) up to 53 250 dB·cm/g, which is higher than the values reported for other carbon- and metal-based shields. Furthermore, the critical roles that microstructures play in determining the EMI shielding performance are directly revealed by comparing the shielding performance in directions parallel and normal to cell walls, as well as in an in situ compression process.

Lignin is an attractive renewable reinforcing agent for polyolefins and also a promising low-cost antioxidant for polymers. It, however, exhibits poor compatibility with nonpolar polymers. In this work, alkali lignin was freeze-dried to achieve sheet-like morphology and then incorporated into polypropylene (PP) by melt compounding. Owing to the significantly increased interfacial area and improved dispersion, with the addition of only 2 wt % freeze-dried lignin, the PP/ lignin composites show much enhanced tensile mechanical properties, including a moderately improved Young's modulus and almost doubled elongation at break compared with those of neat PP. The enhancements brought by the sheet-like lignin are far more impressive than those achieved with the same amount of as-received lignin. The composites with the freezedried lignin also have rough fractured surfaces with fiber pull-out near the interface, revealing a significant toughening effect of the lignin, which can be attributed to the crazing near the interface, and enhanced relaxation in PP-lignin interphase as evidenced by the reduced T g . Furthermore, the large interfacial area also drastically improves the antioxidant effect of lignin, greatly slowing the UV-induced and thermo-oxidative degradation of PP. After 2 weeks of intense UV exposure, neat PP becomes very brittle with its yield strain reduced to about 37% of its original value, whereas the yield strain of the composite with 2 wt % sheet-like lignin is almost unchanged, demonstrating the excellent free-radical scavenger effect of the lignin.

Nanocomposite strain sensors composed of compressed honeycomb-like reduced-graphene-oxide (RGO) foam embedded in polydimethylsiloxane are facilely fabricated via unidirectional freeze-drying and simple mechanical compression. The microstructural characteristics of the nanocomposites endow the sensors with excellent flexibility, high stretchability and sensing sensitivity, as well as anisotropic mechanical and sensing performance when stretched along directions vertical and parallel to the aligned RGO cell walls (defined as transverse and longitudinal directions, respectively). In particular, the compression of the aligned RGO foam into a thinner film results in more conductive pathways, greatly increasing the sensing sensitivity of the nanocomposite sensors. The sensors stretched along the transverse direction show an outstanding combination of high stretchability over 120%, wide linear sensing region of 0-110% and high strain sensing sensitivity with a gauge factor of around 7.2, while even higher strain sensitivity and lower sensing strain are exhibited along the longitudinal direction. Sensitive and reliable detection of human motions is also successfully demonstrated using these light-weight thin-film nanocomposite sensors.