Foams based on polyetherimide (PEI) with carbon nanotubes (CNT) and PEI with graphene nanoplatelets (GnP) combined with CNT were prepared by water vapor induced phase separation. Prior to foaming, variable amounts of only CNT (0.1–2.0 wt %) or a combination of GnP (0.0–2.0 wt %) and CNT (0.0–2.0 wt %) for a total amount of CNT-GnP of 2.0 wt %, were dispersed in a solvent using high power sonication, added to the PEI solution, and intensively mixed. While the addition of increasingly higher amounts of only CNT led to foams with more heterogeneous cellular structures, the incorporation of GnP resulted in foams with finer and more homogeneous cellular structures. GnP in combination with CNT effectively enhanced the thermal stability of foams by delaying thermal decomposition and mechanically-reinforced PEI. The addition of 1.0 wt % GnP in combination with 1.0 wt % CNT resulted in foams with extremely high electrical conductivity, which was related to the formation of an optimum conductive network by physical contact between GnP layers and CNT, enabling their use in electrostatic discharge (ESD) and electromagnetic interference (EMI) shielding applications. The experimental electrical conductivity values of foams containing only CNT fitted well to a percolative conduction model, with a percolation threshold of 0.06 vol % (0.1 wt %) CNT.

Due to their high mechanical and transport properties, graphene-derived materials have aroused a great deal of interest in the most varied sectors. Among these, graphene nanoplatelets have been gaining interest due to the fact they can be synthesized in a way scalable to mass production, enabling them to be considered in the preparation of polymer nanocomposites. Nevertheless, the addition of graphene nanoplatelets into polymers using industrial melt-mixing machinery is still a challenge, mainly related to inadequate graphene dispersion during processing. Foaming could come as a possible strategy to maximize the efficiency of graphene nanoplatelets in polymers by improving its dispersion throughout the polymer matrix, at the same time enabling to considerably reduce the material's density. This paper considers experimental examples of the improvement of the specific mechanical properties and enhancement of the electrical conductivity of different types of polymer foams thought for the most varied applications by incorporating graphene nanoplatelets using conventional plastic processing technologies, with the goal of developing new multifunctional lightweight polymer nanocomposites.

Polysulfone (PSU) foams containing 0–10 wt% graphene nanoplatelets (GnP) were prepared using two foaming methods. Alongside the analysis of the cellular structure, their thermal conductivity was measured and analyzed. The results showed that the presence of GnP can affect the cellular structure of the foams prepared by both water vapor induced phase separation (WVIPS) and supercritical CO₂ (scCO₂) dissolution; however, the impact is greater in the case of foams prepared by WVIPS. In terms of thermal conductivity, the analysis showed an increasing trend by incrementing the amount of GnP and increasing relative density, with the tortuosity of the cellular structure, dependent on the used foaming method, relative density, and amount of GnP, playing a key role in the final value of thermal conductivity. The combination of all these factors showed the possibility of preparing PSU-GnP foams with enhanced thermal conductivity at lower GnP amount by carefully controlling the cellular structure and relative density, opening up their use in lightweight heat dissipators.