Effect of Hybrid Carbon Fillers on the Electrical and Morphological Properties of Polystyrene Nanocomposites in Microinjection Molding

Revealing microscale bulk structures in polymer-carbon nanocomposites using spin-echo SANS

We have used spin-echo small-angle neutron scattering (SESANS) to probe the hierarchy of structures present in polymer-carbon nanocomposites, with length scales spanning over three orders of magnitude, from 10 nm to 16 μm. The data processing and reduction show a unified approach across two SESANS instruments (TU Delft and Larmor at the ISIS neutron source) and yield consistent data that are able to be modelled using well-established hierarchical models in freely available software such as SasView. Using this approach, we are able to extend the measured length scales by over an order of magnitude compared to traditional scattering methods. This yields information about the structure in the bulk that is inaccessible with conventional scattering techniques (SANS/SAXS) and points to a way for interrogating and investigating polymer nanocomposites routinely across multiple length scales.

Influence of mold cavity thickness on electrical, morphological and thermal properties of polypropylene/carbon micromoldings

In this work, a comparative study on the electrical conductivity (σ) and thermal properties of polypropylene (PP)/carbon microparts with different part thickness (namely, 0.85 and 0.50 mm) is reported. Two different types of carbon filler (i.e., CNT and CB) were adopted to study the efficacy of different carbon fillers in improving the σ of PP/carbon microparts. In general, the σ of 0.85 mm thickness microparts were higher than the 0.50 mm thickness microparts, regardless of the carbon filler type and testing directions. This suggested that higher shearing conditions that prevailed in the microinjection molding (μIM) process were unfavorable for the formation of intact conductive pathways in corresponding moldings, albeit the distribution of carbon fillers turned better with increasing shear rates, as confirmed by morphology observations. The thermal stability of PP/carbon microparts increased with increasing filler concentration. Moreover, the increase of thermal stability was more appreciable for CB-filled microparts which was related to the formation of a CB network structure arising from the use of Ketjenblack® EC-600JD CB that characterized by high surface area (∼1400 m2/g). Differential scanning calorimetry results showed that prior thermomechanical histories (including melt blending and μIM) experienced by the polymer melts had an influence on the thermal behavior of subsequent moldings. Also, there existed a strong shear flow-induced crystallization of polymer chains during μIM because the crystallinity of microparts was higher than that of feed materials.

Enhanced Functional Properties of Low-Density Polyethylene Nanocomposites Containing Hybrid Fillers of Multi-Walled Carbon Nanotubes and Nano Carbon Black

In this work, hybrid filler systems consisting of multi-walled carbon nanotubes (MWCNTs) and nano carbon black (nCB) were incorporated by melt mixing in low-density polyethylene (LDPE). To hybrid systems a mixture of MWCNTs and nCB a mass ratio of 1:1 and 3:1 were used. The purpose was to study if the synergistic effects can be achieved on tensile strength and electrical and thermal conductivity. The dispersion state of carbon nanofillers in the LDPE matrix has been evaluated with scanning electron microscopy. The melting and crystallization behavior of all nanocomposites was not significantly influenced by the nanofillers. It was found that the embedding of both types of carbon nanofillers into the LDPE matrix caused an increase in the value of Young’s modulus. The results of electrical and thermal conductivity were compared to LDPE nanocomposites containing only nCB or only MWCNTs presented in earlier work LDPE/MWCNTs. It was no synergistic effects of nCB in multi-walled CNTs and nCB hybrid nanocomposites regarding mechanical properties, electrical and thermal conductivity, and MWCNTs dispersion. Since LDPE/MWCNTs nanocomposites exhibit higher electrical conductivity than LDPE/MWCNTs + nCB or LDPE/nCB nanocomposites at the same nanofiller loading (wt.%), it confirms our earlier study that MWCNTs are a more efficient conductive nanofiller. The presence of MWCNTs and their concentration in hybrid nanocomposites was mainly responsible for the improvement of their thermal conductivity.

Novel Unsaturated Polyester Nanocomposites via Hybrid 3D POSS-Modified Graphene Oxide Reinforcement: Electro-Technical Application Perspective

The latest trends in technologies has shifted the focus to developing innovative methods for comprehensive property enhancement of the polymer composites with facile and undemanding experimental techniques. This work reports an elementary technique to fabricate high-performance unsaturated polyester-based nanocomposites. It focuses on the interactive effect of polyhedral oligomeric silsesquioxanes (POSS)-functionalized graphene oxide (GO) within the unsaturated polymermatrix. The hybrid framework of POSS-functionalized graphene oxide has been configured via peptide bonding between the aminopropyl isobutyl POSS and graphene oxide. The synergistic effect of POSS and graphene oxide paved the way for a mechanism to inculcate a hybrid framework within the unsaturated polyester (UP) via in situ polymerization to develop UP/GO-POSS nanocomposites. The surface-appended POSS within the graphene oxide boosted its dispersion in the UP matrix, furnishing an enhancement in tensile strength of the UP/GO-POSS composites by 61.9%, thermal decomposition temperature (10% mass loss) by 69.8 °C and electrical conductivity by 10⁸ S/m, in contrast to pure UP. In particular, the homogenous influence of the POSS-modified GO could be vindicated in the surging of the limiting oxygen index (%) in the as-prepared nanocomposites. The inclusive property amelioration vindicates the use of fabricated nanocomposites as high-performance nanomaterials in electrotechnical applications.

Injection-molded lightweight and high electrical conductivity composites with microcellular structure and hybrid fillers

Polypropylene/carbon black (PP/CB) and PP/CB/multiwalled carbon nanotube (PP/CB/MWCNT) composites were fabricated by solid and foam injection molding, with the goal of enhancing the electrical conductivity of the composites while decreasing the cost of the final product. The foaming behavior and through-plane (T-P) electrical conductivity of the composites were characterized and analyzed. Cell growth increased the interconnection of the conductive fillers, changed the filler orientation, and enhanced the T-P electrical conductivity of the composites. Under appropriate processing conditions (200°C melt temperature, 70 cm3/s injection flow rate, and 5% void fraction), the T-P electrical conductivity of the foam PP/CB composites was 5 orders of magnitude higher than that of the solid composites (from 5.877 × 10−12 S/m to 1.010 × 10−7 S/m). Moreover, the T-P electrical conductivity values of the PP/CB and PP/CB/MWCNT were compared at the same conductive fillers content (15 wt%). The results showed that the T-P electrical conductivity of the PP/CB/MWCNT composites was far higher than that of the PP/CB composites by almost five orders of magnitude because the MWCNT acted as a bridge between CB particles, and a unique geometric shape was formed in the system. The T-P electrical conductivity of the foam PP/CB/MWCNT composites with 15 wt% carbon fillers was higher than that of the solid PP/CB composites with 20 wt% carbon fillers. This study reveals that the effect of foaming and the addition of hybrid fillers can improve the T-P electrical conductivity of plastic products, which is very important for the development of lightweight conductive plastics.

Graphene Nanoplatelet-Reinforced Poly(vinylidene fluoride)/High Density Polyethylene Blend-Based Nanocomposites with Enhanced Thermal and Electrical Properties

In this study, a graphene nanoplatelet (GNP) was used as a reinforcing filler to prepare poly(vinylidene fluoride) (PVDF)/high density polyethylene (HDPE) blend-based nanocomposites through a melt mixing method. Scanning electron microscopy confirmed that the GNP was mainly distributed within the PVDF matrix phase. X-ray diffraction analysis showed that PVDF and HDPE retained their crystal structure in the blend and composites. Thermogravimetric analysis showed that the addition of GNP enhanced the thermal stability of the blend, which was more evident in a nitrogen environment than in an air environment. Differential scanning calorimetry results showed that GNP facilitated the nucleation of PVDF and HDPE in the composites upon crystallization. The activation energy for non-isothermal crystallization of PVDF increased with increasing GNP loading in the composites. The Avrami n values ranged from 1.9⁻3.8 for isothermal crystallization of PVDF in different samples. The Young's and flexural moduli of the blend improved by more than 20% at 2 phr GNP loading in the composites. The measured rheological properties confirmed the formation of a pseudo-network structure of GNP-PVDF in the composites. The electrical resistivity of the blend reduced by three orders at a 3-phr GNP loading. The PVDF/HDPE blend and composites showed interesting application prospects for electromechanical devices and capacitors.

From Hollow to Solid Carbon Spheres: Time-Dependent Facile Synthesis

Here, we report a facile route for obtaining carbon spheres with fully tunable shell thickness. Using a hard template in chemical vapor deposition (CVD), hollow carbon spheres, solid carbon spheres, and intermediate structures can be obtained with optimized process time. The resulting carbon spheres with particle diameters of ~400 nm, as well as a controllable shell thickness from 0 to 70 nm, had high Brunauer–Emmett–Teller (BET) specific surface area (up to 344.8 m²·g⁻¹) and pore volume (up to 0.248 cm³·g⁻¹). The sphere formation mechanism is also proposed. This simple and reproducible technique can deliver carbon materials for various applications, e.g., energy storage and conversion, adsorption, catalytic, biomedical, and environmental applications.