Point-Line Conductive Networks via Carbon Black/Multi-Walled Carbon Nanotube Hybrid Fillers and Surfactant Modification in Silicone Rubber Electromagnetic Shielding Composites

Constructing efficient conductive networks in flexible polymer matrices remains a central challenge in electromagnetic interference (EMI) shielding material design. In this work, a ‘point-line’ hybrid filler system combining conductive carbon black (CB) and multi-walled carbon nanotubes (MWCNTs) was incorporated into a silicone rubber matrix to systematically engineer the conductive network architecture. By optimising the CB/MWCNT blending ratio, a composite with a tensile strength of 8.5 MPa, elongation at break of 180%, and EMI shielding effectiveness of 50 dB was achieved at a 1:1 weight ratio. Further surface modification of the hybrid fillers using five surfactants, including sodium dodecylbenzene sulfonate (SDBS), cetyltrimethylammonium bromide (CTAB), polyvinylpyrrolidone (PVP), nonylphenol ethoxylate (NPEO), and octylphenol ethoxylate (OPEO), was systematically investigated. OPEO modification was proved the most effective, improving EMI shielding performance to 58 dB while enhancing tensile strength by 11.8% and elongation at break by 50%. These results demonstrate that rational filler hybridisation combined with targeted surfactant modification offers a practical and scalable route to high-performance flexible EMI shielding composites.