Ultralight activated carbon/polyimide foam with heterogeneous interfaces for improved thermal stability, mechanical properties, and microwave absorption

Abstract The activated carbon (AC) has been widely used in the field of electromagnetic protection because of its porous, hollow microstructure and excellent electrical conductivity. In this paper, AC was prepared through KOH activation process. The ACs/polyimide foam (PIF) composite was prepared in situ during the synthesis of PI and the ACs. In this paper, AC was prepared using the potassium hydroxide (KOH) activation process. The AC/PIF composites were prepared by mixing ACs and pyromellitic dianhydride (PMDA) with methylene diphenyl diisocyanate (MDI). The pore structure and surface morphology of the ACs were observed using nitrogen adsorption–desorption isotherms and scanning electron microscopy (SEM). After KOH activation with KOH, the surface area and total pore volume of ACs significantly increased by 79.31% and 0.9539 cm 3 /g, respectively, mainly were the microporous structure. X‐ray photoelectron spectroscopy (XPS) results confirmed an increase in the oxygen content of ACs after KOH activation, indicating an increase in the relative hydroxyl content on the surface. The SEM resulting of the ACs/PIF composite has a well‐developed open cell structure. Thermal gravimetric analysis (TGA) revealed that ACs significantly improved the thermal stability of the ACs/PIF composite. The compressive strength of the ACs/PIF‐3 increased from 518 to 834 KPa, significantly enhancing its mechanical properties. Simultaneously, the microwave absorption performance can be controlled and regulated by optimizing the impedance gradient of the skeleton. Results showed that when ACs constituted 8 wt% of the PIF, the real permittivity ( ɛ ′) and imaginary permittivity ( ɛ ″) of ACs‐PIF‐5 were approximately 2.03 and 0.025, respectively.