In order to obtain a conductive composite with excellent electrical performance and mechanical properties, a unique continuous segregated structure was constructed for PP/CB composites. In this novel continuous segregated structure, the CB particles form a thorough 2-D conductive network and the PP matrix also maintains a continuous structure instead of being separated completely by conductive fillers at the same time. The continuous segregated structure was fabricated by selectively removing the PS phase in PP/PS/CB composites and then compressing the obtained porous PP/CB composites again at 160 ℃. After that, the morphology, electrical performance and mechanical properties were characterized. The morphology observation showed that the continuous segregated structure was constructed successfully as expected. An extremely low percolation threshold (0.37 vol.%), which is significantly lower than conventional PP/CB composites and PP/PS/CB composites (a double percolation structure), was obtained due to the effective use of CB particles. Moreover, the mechanical properties of the continuous segregated materials can be maintained well when the percolation threshold appears. All results showed that, with this continuous segregated structure, the composites exhibited an excellent balance between the electrical performance and mechanical properties because of the effective 2-D CB conductive network and the continuous structure of PP matrix. This is a new and effective approach to reduce the percolation threshold and balance the mechanical properties and electrical conductivity at a very low conductive filler concentration.