Structuring tri-continuous structure multiphase composites with ultralow conductive percolation threshold and excellent electromagnetic shielding effectiveness using simple melt mixing

•Tri-continuous structure in PVDF/PS/HDPE-MWCNTs composite is successfully formed by melt mixing.•The composite shows an ultralow conductive percolation threshold of 0.022 vol%.•The composite maintains good conductive reproducibility after five times of processing.•The composite displays good shielding effectiveness of 31 dB with only 1.6 vol% MWCNTs loading at 9.5 GHz.

Tri-continuous structure poly(vinylidene fluoride)/polystyrene/high density polyethylene (PVDF/PS/HDPE) ternary blends was fabricated as a candidate for structuring high electrical performance composites. By adding MWCNTs and tuning the thermodynamic and kinetics conditions, the selective distribution of MWCNTs in interfacial PS phase were formed after melt mixing. These composites displayed ultralow conductive percolation threshold and excellent electromagnetic shielding effectiveness by this structuring process.

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