Graphene-Based Hybrid Fillers for Rubber Composites

Graphene and its derivatives have been confirmed to be among the best fillers for rubber due to their excellent properties, such as high mechanical strength, improved interface interaction, and strain-induced crystallization capabilities. Graphene rubber materials can be widely used in tires, shoes, high-barrier conductive seals, electromagnetic shielding seals, shock absorbers, etc. In order to reduce the graphene loading and endow more desirable functions to rubber materials, graphene-based hybrid fillers are extensively employed, which can effectively enhance the performance of rubber composites. This review briefly summarizes the recent research on rubber composites with graphene-based hybrid fillers consisting of carbon black, silica, carbon nanotubes, metal oxide, and one-dimensional nanowires. The preparation methods, performance improvements, and applications of different graphene-based hybrid fillers/rubber composites have been investigated. This study also focuses on methods that can ensure the effectiveness of graphene hybrid fillers in reinforcing rubber composites. Furthermore, the enhanced mechanism of graphene- and graphene derivative-based hybrid fillers in rubber composites is investigated to provide a foundation for future studies.

Enhanced Thermal Conductivity of High-Density Polyethylene Composites with Hybrid Fillers of Flaky and Spherical Boron Nitride Particles

The synergistic effect between different fillers plays a crucial role in determining the performance of composites. In this work, spherical boron nitride (BN) and flaky BN are used as hybrid fillers to improve the thermal conductivity (TC) of high-density polyethylene (HDPE) composites. A series of HDPE composites were prepared by adjusting the mass ratio (1:0, 4:1, 2:1, 1:1, 1:2, 1:4, and 0:1) of spherical BN and flaky BN. The SEM results indicate that the spherical BN (with a particle size of 3 μm) effectively filled the gaps between the flaky BN (with a particle size of 30 μm), leading to the formation of more continuous heat conduction paths with the composite. Remarkably, when the mass ratio of spherical BN to flaky BN was set to 1:4 (with a total BN filling amount of 30 wt%), the TC of the composite could reach up to 1.648 Wm-1K-1, which is obviously higher than that of the composite containing a single filler, realizing the synergistic effect of the hybrid fillers. In addition, the synergistic effect of fillers also affects the thermal stability and crystallization behavior of composites. This work is of great significance for optimizing the application of hybrid BN fillers in the field of thermal management.

PEO-Based Solid Composite Polymer Electrolyte for High Capacity Retention All-Solid-State Lithium Metal Battery

The limited ionic conductivity at room temperature and the constrained electrochemical window of poly(ethylene oxide) (PEO) pose significant obstacles that hinder its broader utilization in high-energy-density lithium metal batteries. The garnet-type material Li6.4 La3 Zr1.4 Ta0.6 O12 (LLZTO) is recognized as a highly promising active filler for enhancing the performance of PEO-based solid polymer electrolytes (SPEs). However, its performance is still limited by its high interfacial resistance. In this study, a novel hybrid filler-designed SPE is employed to achieve excellent electrochemical performance for both the lithium metal anode and the LiFePO4 cathode. The solid composite membrane containing hybrid fillers achieves a maximum ionic conductivity of 1.9 × 10-4 S cm-1 and a Li+ transference number of 0.67 at 40 °C, respectively. Additionally, the Li/Li symmetric cells demonstrate a smooth and stable process for 2000 h at a current density of 0.1 mA cm-2 . Furthermore, the LiFePO4 /Li battery delivers a high-rate capacity of 159.2 mAh g-1 at 1 C, along with a capacity retention of 95.2% after 400 cycles. These results validate that employing a composite of both active and inactive fillers is an effective strategy for achieving superior performance in all-solid-state lithium metal batteries (ASSLMBs).

Improved Heat Dissipation of NR/SBR-Based Tire Tread Compounds via Hybrid Fillers of Multi-Walled Carbon Nanotube and Carbon Black

The development of thermally conductive rubber nanocomposites for heat management poses a formidable challenge in numerous applications, notably within the realm of tire technology. Notably, rubber materials are characterized by their inherently low thermal conductivity. Consequently, it becomes imperative to incorporate diverse conductive fillers to mitigate the propensity for heat build-up. Multi-walled carbon nanotubes (MWCNTs), as reinforcement agents within the tire tread compounds, have gained considerable attention owing to their extraordinary attributes. The attainment of high-performance rubber nanocomposites hinges significantly on the uniform distribution of MWCNT. This study presents the influence of MWCNTs on the performance of carbon black (CB)-reinforced natural rubber (NR)/styrene butadiene rubber (SBR) tire compounds prepared via high shear melt mixing. Morphological analysis showed a good distribution of MWCNTs in the NR/SBR/CB compound. The vulcanization parameters, such as the maximum and minimum torque, cross-linking density, hardness, abrasion resistance, tensile strength, and Young modulus, exhibited a progressive improvement with the addition of MWCNT. Remarkably, adding MWCNT into CB improved the heat conductivity of the NR/SBR/CB compounds, hence decreasing the heat build-up. A percolation mode was also proposed for the hybrid carbon fillers based on the data obtained.

Toward Three-Dimensional Printed Thermal Conductive Polymeric Composites Using a Binary-Composite Hybrid Based on Boron Nitride Nanoparticles and Micro-Diamonds

Thermally conductive polymeric composites are promising for heat management in microelectronic devices. This work presents a binary-hybrid composite of boron nitride (BN) nanoparticles and micro-diamond (D) fillers in an elastomeric polyurethane (PU) matrix which can be three- dimensionally printed to produce a highly flexible and self-supporting structure. The research shows that a combination of 16.7 wt% BN and 16.7 wt% D results in a robust network within the polymer matrix to improve the tensile modulus more than nine times with respect to neat PU. Significantly, the hybrid matrix enhances the thermal conductivity by more than two times when compared to neat PU. The enhancement in mechanical, and thermal features make this three-dimensional printable multiscale hybrid composite suitable for flexible and stretchable microelectronic applications.

Hybrid Carbon Microfibers-Graphite Fillers for Piezoresistive Cementitious Composites

Multifunctional structural materials are very promising in the field of engineering. Particularly, their strain sensing ability draws much attention for structural health monitoring applications. Generally, strain sensing materials are produced by adding a certain amount of conductive fillers, around the so-called “percolation threshold”, to the cement or composite matrix. Recently, graphite has been found to be a suitable filler for strain sensing. However, graphite requires high amounts of doping to reach percolation threshold. In order to decrease the amount of inclusions, this paper proposes cementitious materials doped with new hybrid carbon inclusions, i.e., graphite and carbon microfibers. Carbon microfibers having higher aspect ratio than graphite accelerate the percolation threshold of the graphite particles without incurring into dispersion issues. The resistivity and strain sensitivity of different fibers’ compositions are investigated. The electromechanical tests reveal that, when combined, carbon microfibers and graphite hybrid fillers reach to percolation faster and exhibit higher gauge factors and enhanced linearity.

Straw/Nano-Additive Hybrids as Functional Fillers for Natural Rubber Biocomposites

Currently, up to 215 million metric tons of harvestable straw are available in Europe, 50% of the crops come from wheat, 25% from barley and 25% from maize. More than half of the production remains undeveloped. The overproduction of straw in the world means that the current methods of its management are insufficient. The article describes the production method and characterization of natural rubber biocomposites containing cereal straw powder modified with functional nano-additives in the form of carbon black, silica and halloysite nanotubes. The use of cereal straw in the elastomer matrix should contribute to obtaining a product with good mechanical properties while ensuring a low cost of the composite. In turn, the application of the mechanical modification process will allow the combination of specific properties of raw materials to obtain new, advanced elastomeric materials. As part of the work, hybrid fillers based on mechanically modified cereal straw were produced. The impact of hybrid fillers on mechanical, rheometric and damping properties was assessed. The flammability and susceptibility of the obtained biocomposites to aging processes were determined. The use of hybrid fillers based on mechanically modified straw allowed us to obtain a higher cross-linking density of vulcanizates (even up to 40% compared to the reference sample), and thus higher values of the rheometric moment during the vulcanization process of rubber mixtures (from approx. 10% (10 phr of filler) up to 50% (30 phr of filler) in relation to the unfilled system) and higher hardness of vulcanizates (by about 30–70%). The curing time of the blends was slightly longer, but the obtained composites were characterized by significantly higher tensile strength. The use of fillers in the elastomer matrix increased the modulus at 100, 200 and 300% and the elongation at break. Moreover, greater resistance of vulcanizates to the combustion process was confirmed.

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

The effect of hybrid carbon fillers of multi-walled carbon nanotubes (CNT) and carbon black (CB) on the electrical and morphological properties of polystyrene (PS) nanocomposites were systematically investigated in microinjection molding (μIM). The polymer nanocomposites with three different filler concentrations (i.e., 3, 5 and 10 wt %) at various weight ratios of CNT/CB (100/0, 30/70, 50/50, 70/30, 0/100) were prepared by melt blending, then followed by μIM under a defined set of processing conditions. A rectangular mold insert which has three consecutive zones with decreasing thickness along the flow direction was adopted to study abrupt changes in mold geometry on the properties of resultant microparts. The distribution of carbon fillers within microparts was observed by scanning electron microscopy, which was correlated with electrical conductivity measurements. Results indicated that there is a flow-induced orientation of incorporated carbon fillers and this orientation increased with increasing shearing effect along the flow direction. High structure CB is found to be more effective than CNT in terms of enhancing the electrical conductivity, which was attributed to the good dispersion of CB in PS and their ability to form conductive networks via self-assembly. Morphology observations indicated that there is a shear-induced depletion of CB particles in the shear layer, which is due to the marked difference of shear rates between the shear and core layers of the molded microparts. Moreover, an annealing treatment is beneficial to enhance the electrical conductivity of CNT-containing microparts.

Experimental Investigation of the Piezoresistive Properties of Cement Composites with Hybrid Carbon Fibers and Nanotubes

Cement-based sensors with hybrid conductive fillers using both carbon fibers (CFs) and multi-walled carbon nanotubes (MWCNTs) were experimentally investigated in this study. The self-sensing capacities of cement-based composites with only CFs or MWCNTs were found based on preliminary tests. The results showed that the percolation thresholds of CFs and MWCNTs were 0.5–1.0 vol.% and 1.0 vol.%, respectively. Based on these results, the feasibility of self-sensing composites with four different amounts of CFs and MWCNTs was considered under cyclic compression loads. When the amount of incorporated CFs increased and the amount of incorporated MWCNTs decreased, the self-sensing capacity of the composites was reduced. It was concluded that cement-based composites containing both 0.1 vol.% CFs and 0.5 vol.% MWCNTs could be an alternative to cement-based composites with 1.0 vol.% MWCNTs in order to achieve equivalent self-sensing performance at half the price. The gauge factor (GF) for that composite was 160.3 with an R-square of 0.9274 in loading stages I and II, which was similar to the GF of 166.6 for the composite with 1.0 vol.% MWCNTs.