Conductive Polymer Foaming: A Review on Fundamentals, Technology and Applications

Conductive polymer microcellular foamed materials are a type of functional composite that combines lightweight cell structures with controllable conductivity. Their core feature lies in regulating the cell structure of the material through microcellular foaming technology, along with the introduction of conductive fillers or the intrinsic conductivity of the polymer, to achieve enhanced electrical performance. This paper systematically reviews conductive polymers and their microcellular foamed materials, highlighting research progress in foaming mechanisms, preparation processes, and functional applications. It first analyzes the key mechanisms of bubble nucleation, growth, and stabilization during the microcellular foaming of conductive polymers. Then, it elaborates on the research status and functional mechanisms of these materials in three typical application scenarios: electromagnetic shielding, flexible sensors, and thermal management. Finally, it outlines the future development directions of conductive polymer microcellular foamed materials in multifunctional integration, green fabrication, and intelligent applications, aiming to provide theoretical guidance and technical pathways for future research.