3D Graphene-Infused Polyimide with Enhanced Electrothermal Performance for Long-Term Flexible Space Applications

Surface-Localized Chemically Modified Reduced Graphene Oxide Nanocomposites as Flexible Conductive Surfaces for Space Applications

Thermoplastic polymers are a compelling class of materials for emerging space exploration applications due to their wide range of mechanical properties and compatibility with a variety of processing methods, including additive manufacturing. However, despite these benefits, the use of thermoplastic polymers in a set of critical space applications is limited by their low electrical conductivity, which makes them susceptible to static charging and limits their ability to be used as active and passive components in electronic devices, including materials for static charge dissipation, resistive heaters, and electrodynamic dust shielding devices. Herein, we explore the microstructural evolution of electrically conductive, surface-localized nanocomposites (SLNCs) of chemically modified reduced graphene oxide and a set of thermoplastic polymers as a function of critical thermal properties of the substrate (melting temperature for semi-crystalline materials or glass transition temperature for amorphous materials). Selected offsets from critical substrate temperatures were used to produce SLNCs with conductivities between 0.6-3 S/cm and surface structures, which ranged from particle-rich, porous surfaces to polymer-rich, non-porous surfaces. We then demonstrate the physical durability of these electrically conductive SLNCs to expected stress conditions for flexible conductive materials in lunar applications including tension, flexion, and abrasion with lunar simulant. Small changes in resistance (R/R₀ < 2) were measured under uniaxial tension up to 20% strain in high density polyethylene and up to 500 abrasion cycles in polysulfone, demonstrating the applicability of these materials as active and passive flexible conductors in exterior lunar applications. The tough, electrically conductive SLNCs developed here could greatly expand the use of polymeric materials in space applications, including lunar exploration, micro- and nano-satellites, and other orbital structures.

Experimental, Theoretical and Numerical Studies on Thermal Properties of Lightweight 3D Printed Graphene-Based Discs with Designed Ad Hoc Air Cavities

The current state of the art on material science emphasizes recent research efforts aimed at designing novel materials characterized by low-density and advanced properties. The present article reports the experimental, theoretical and simulation results on the thermal behavior of 3D printed discs. Filaments of pure poly (lactic acid) PLA and filled with 6 wt% of graphene nanoplatelets (GNPs) are used as feedstocks. Experiments indicate that the introduction of graphene enhances the thermal properties of the resulting materials since the conductivity passes from the value of 0.167 [W/mK] for unfilled PLA to 0.335 [W/mK] for reinforced PLA, which corresponds to a significantly improvement of 101%. Exploiting the potential of 3D printing, different air cavities have been intentionally designed to develop new lightweight and more cost-effective materials without compromising their thermal performances. Furthermore, some cavities are equal in volume but different in the geometry; it is necessary to investigate how this last characteristic and its possible orientations affect the overall thermal behavior compared to that of an air-free specimen. The influence of air volume is also investigated. Experimental results are supported by theoretical analysis and simulation studies based on the finite element method. The results aim to be a valuable reference resource in the field of design and optimization of lightweight advanced materials.

From Protosolar Space to Space Exploration: The Role of Graphene in Space Technology and Economy

This paper aims to analyse the state-of-the-art of graphene-based materials and devices designed for use in space. The goal is to summarise emerging research studies, contextualise promising findings, and discuss underway strategies to address some specific space-related problems. To complete our overview of graphene-based technology and address the relevance of graphene in the wide scenario of the space economy, we also provide an analysis of worldwide patents and the scientific literature for aerospace applications in the period 2010-2021. We analysed global trends, country distributions, top assignees, and funding sponsors, evidencing a general increase for the period considered. These indicators, integrated with market information, provide a clear evaluation of the related technology trends and readiness levels.

Optimization of Effective Thermal Conductivity of Thermal Interface Materials Based on the Genetic Algorithm-Driven Random Thermal Network Model

Polymer-based thermal interface materials (TIMs) are indispensable for reducing the thermal contact resistance of high-power electronic devices. Owing to the low thermal conductivity of polymers, adding multiscale dispersed particles with high thermal conductivity is a common approach to enhance the effective thermal conductivity. However, optimizing multiscale particle matching, including particle size distribution and volume fraction, for improving the effective thermal conductivity has not been achieved. In this study, three kinds of filler-loaded samples were prepared, and the effective thermal conductivity and average particle size of the samples were tested. The finite element model (FEM) and the random thermal network model (RTNM) were applied to predict the effective thermal conductivity of TIMs. Compared with the FEM, the RTNM achieves higher accuracy with an error less than 5% and higher computational efficiency in predicting the effective thermal conductivity of TIMs. Combining the abovementioned advantages, we designed a set of procedures for an RTNM driven by the genetic algorithm (GA). The procedure can find multiscale particle-matching ways to achieve the maximum effective thermal conductivity under a given filler load. The results show that the samples with 40 vol %, 50 vol %, and 60 vol % filler loading have similar particle size distribution and volume fractions when the effective thermal conductivity reaches the highest. It should be emphasized that the optimized effective thermal conductivity can be improved obviously with the increase in the volume fraction of the filler loading. The high efficiency and accuracy of the procedure show great potential for the future design of high-efficiency TIMs.

Conductive Biomass Films Containing Graphene Oxide and Cationic Cellulose Nanofibers for Electric-Heating Applications

A low-voltage biomass matrix and flexible electric-heating composite with graphene oxide (GO) and cationic cellulose nanofiber (CCNF) were fabricated by ultrasonic dispersion and suction filtration. The main results show that the tensile strength and strain of the films decreased with an increase in the GO content, but the thermal stability increased. The GO/CCNF film underwent rapid thermal decomposition at 250–350 °C, and the maximum degradation temperature was higher by 19 °C compared to that of the pure CCNF film. It was found that the electrical conductivity increased from 0.013 to 2.96 S/cm with an increase in the GO content from 20 to 60 wt%, resulting in an increase in the power density from 122 to 2456 W/m². The films could rapidly attain the temperature within 50 s, and the heat transferred by radiation and convection was 21.62 mW/°C, thereby exhibiting excellent electric heating response. Moreover, the film demonstrated a stable electric-heating cycle after a 12.5 h cycling test and meets the requirements of low-temperature electric heating products under the 36 V electric safety limit, which expands the potential applications of biomass-derived cellulose nanofibers.

Nacre-Inspired Strong and Multifunctional Soy Protein-Based Nanocomposite Materials for Easy Heat-Dissipative Mobile Phone Shell

Inspired by the hierarchically ordered "brick and mortar" (BM) architecture of natural nacre, in this study a rational assembly of boron nitride (BN) nanosheets was introduced into a mixture of trimethylolpropane triglycidyl ether (TTE) and soy protein isolate (SPI), and a strong and multifunctional SPI-based nanocomposite film with multinetwork structure was synthesized. At a low BN loading (<0.5%), the resulting multifunctional film was flexible, antiultraviolet, and nearly transparent and also displayed good thermal diffusion ability and exhibited an excellent combination of high tensile strength (36.4 MPa) and thermal conductivity (TC, 2.40 W·m^-1·K^-1), surpassing the performances of various types of petroleum-based plastics (displayed a tensile strength ranging from 1.9 to 21 MPa and TC ranging from 0.55-2.13 W·m^-1·K^-1), including nine different types of materials currently utilized for mobile phone shells, suggesting its vast potential in practical applications.

3D Graphene Materials: From Understanding to Design and Synthesis Control

Carbon materials, with their diverse allotropes, have played significant roles in our daily life and the development of material science. Following 0D C₆₀ and 1D carbon nanotube, 2D graphene materials, with their distinctively fascinating properties, have been receiving tremendous attention since 2004. To fulfill the efficient utilization of 2D graphene sheets in applications such as energy storage and conversion, electrochemical catalysis, and environmental remediation, 3D structures constructed by graphene sheets have been attempted over the past decade, giving birth to a new generation of graphene materials called 3D graphene materials. This review starts with the definition, classifications, brief history, and basic synthesis chemistries of 3D graphene materials. Then a critical discussion on the design considerations of 3D graphene materials for diverse applications is provided. Subsequently, after emphasizing the importance of normalized property characterization for the 3D structures, approaches for 3D graphene material synthesis from three major types of carbon sources (GO, hydrocarbons and inorganic carbon compounds) based on GO chemistry, hydrocarbon chemistry, and new alkali-metal chemistry, respectively, are comprehensively reviewed with a focus on their synthesis mechanisms, controllable aspects, and scalability. At last, current challenges and future perspectives for the development of 3D graphene materials are addressed.

High porosity and light weight graphene foam heat sink and phase change material container for thermal management

During the last decade, graphene foam emerged as a promising high porosity 3-dimensional (3D) structure for various applications. More specifically, it has attracted significant interest as a solution for thermal management in electronics. In this study, we investigate the possibility to use such porous materials as a heat sink and a container for a phase change material (PCM). Graphene foam (GF) was produced using chemical vapor deposition (CVD) process and attached to a thermal test chip using sintered silver nanoparticles (Ag NPs). The thermal conductivity of the graphene foam reached 1.3 W m-1 K-1, while the addition of Ag as a graphene foam silver composite (GF/Ag) enhanced further its effective thermal conductivity by 54%. Comparatively to nickel foam, GF and GF/Ag showed lower junction temperatures thanks to higher effective thermal conductivity and a better contact. A finite element model was developed to simulate the fluid flow through the foam structure model and showed a positive and a non-negligible contributions of the secondary microchannel within the graphene foam. A ratio of 15 times was found between the convective heat flux within the primary and secondary microchannel. Our paper successfully demonstrates the possibility of using such 3D porous material as a PCM container and heat sink and highlight the advantage of using the carbon-based high porosity material to take advantage of its additional secondary porosity.

Resilient Graphene Ultrathin Flat Lens in Aerospace, Chemical, and Biological Harsh Environments

The development of ultrathin flat lenses has revolutionized the lens technologies and holds great promise for miniaturizing the conventional lens system in integrated photonic applications. In certain applications, the lenses are required to operate in harsh and/or extreme environments, for example aerospace, chemical, and biological environments. Under such circumstances, it is critical that the ultrathin flat lenses can be resilient and preserve their outstanding performance. However, the majority of the demonstrated ultrathin flat lenses are based on metal or semiconductor materials that have poor chemical, thermal, and UV stability, which limit their applications. Herein, we experimentally demonstrate a graphene ultrathin flat lens that can be applied in harsh environments for different applications, including a low Earth orbit space environment, strong corrosive chemical environments (pH = 0 and pH = 14), and biochemical environment. The graphene lenses have extraordinary environmental stability and can maintain a high level of structural integrity and outstanding focusing performance under different test conditions. Thus, it opens tremendous practical application opportunities for ultrathin flat lenses.

Advances in Polyimide-Based Materials for Space Applications

The space environment raises many challenges for new materials development and ground characterization. These environmental hazards in space include solar radiation, energetic particles, vacuum, micrometeoroids and debris, and space plasma. In low Earth orbits, there is also a significant concentration of highly reactive atomic oxygen (AO). This Progress Report focuses on the development of space-durable polyimide (PI)-based materials and nanocomposites and their testing under simulated space environment. Commercial PIs suffer from AO-induced erosion and surface electric charging. Modified PIs and PI-based nanocomposites are developed and tested to resist degradation in space. The durability of PIs in AO is successfully increased by addition of polyhedral oligomeric silsesquioxane. Conductive materials are prepared based on composites of PI and either carbon nanotube (CNT) sheets or 3D-graphene structures. 3D PI structures, which can expand PI space applications, made by either additive manufacturing (AM) or thermoforming, are presented. The selection of AM-processable engineering polymers in general, and PIs in particular, is relatively limited. Here, innovative preliminary results of a PI-based material processed by the PolyJet technology are presented.

Three-dimensional graphene-based polymer nanocomposites: preparation, properties and applications

Motivated by the unique structure and outstanding properties of graphene, three-dimensional (3D) graphene-based polymer nanocomposites (3D-GPNCs) are considered as new generation materials for various multi-functional applications. This review presents an overview of the preparation, properties and applications of 3D-GPNCs. Three main approaches for fabricating 3D-GPNCs, namely 3D graphene based template, polymer particle/foam template, and organic molecule cross-linked graphene, are introduced. A thorough investigation and comparison of the mechanical, electrical and thermal properties of 3D-GPNCs are performed and discussed to understand their structure-property relationship. Various potential applications of 3D-GPNCs, including energy storage and conversion, electromagnetic interference shielding, oil/water separation, and sensors, are reviewed. Finally, the current challenges and outlook of these emerging 3D-GPNC materials are also discussed.

Hydrogen Bond-Regulated Boron Nitride Network Structures for Improved Thermal Conductive Property of Polyamide-imide Composites

Highly thermal conductive polymer composites with minimized content of fillers are desirable for handling the issue in thermal management in modern electronics. However, the difficulty of filler dispersion restricts the heat dissipation performance of thermoplastic composites and the intermolecular interaction is another crucial factor in this problem. In the present study, the hydrogen bond was used to regulate the formation of the three-dimensional boron nitride (3D BN) interconnected network to act as a high thermal conductive network in thermoplastic polyamide-imide (PAI) materials. The prepared electrical insulated PAI/3D-BN composites have a thermal conductivity (TC) of 1.17 W·m^-1·K^-1 at a low BN loading of 4 wt %/2 vol % and exhibit a thermal conductivity enhancement of 409%. We attribute the increased TC to the construction of 3D BN interconnected network and the hydrogen bond regulated between hydroxylated BN and polyvinyl alcohol, in which an effective thermal conductive network is constructed. This study provides a guided hydrogen bond strategy for thermally conductive polymer composites with good mechanical and electrical insulation properties in thermal management and other applications.

3D graphene-based nanostructured materials as sorbents for cleaning oil spills and for the removal of dyes and miscellaneous pollutants present in water

Oil spills over seawater and dye pollutants in water cause economic and environmental damage every year. Among various methods to deal oil spill problems, the use of porous materials has been proven as an effective strategy. In recent years, graphene-based porous sorbents have been synthesized to address the shortcomings associated with conventional sorbents such as their low uptake capacity, slow sorption rate, and non-recyclability. This article reviews the research undertaken to control oil spillage using three-dimensional (3D) graphene-based materials. The use of these materials for removal of dyes and miscellaneous environmental pollutants from water is explored and the application of various multifunctional 3D oil sorbents synthesized by surface modification technique is presented. The future prospects and limitations of these materials as sorbents are also discussed.

Significant Enhancement of Thermal Conductivity in Nanofibrillated Cellulose Films with Low Mass Fraction of Nanodiamond

High thermal conductive nanofibrillated cellulose (NFC) hybrid films based on nanodiamond (ND) were fabricated by a facile vacuum filtration technique. In this issue, the thermal conductivity (TC) on the in-plane direction of the NFC/ND hybrid film had a significant enhancement of 775.2% at a comparatively low ND content (0.5 wt %). The NFC not only helps ND to disperse in the aqueous medium stably but also plays a positive role in the formation of the hierarchical structure. ND could form a thermal conductive pathway in the hierarchical structures under the intermolecular hydrogen bonds. Moreover, the hybrid films composed of zero-dimensional ND and one-dimensional NFC exhibit remarkable mechanical properties and optical transparency. The NFC/ND hybrid films possessing superior TC, mechanical properties, and optical transparency can open applications for portable electronic equipment as a lateral heat spreader.

Polymer Composite with Improved Thermal Conductivity by Constructing a Hierarchically Ordered Three-Dimensional Interconnected Network of BN

In this work, we report a fabrication of epoxy resin/ordered three-dimensional boron nitride (3D-BN) network composites through combination of ice-templating self-assembly and infiltration methods. The polymer composites possess much higher thermal conductivity up to 4.42 W m^-1 K^-1 at relatively low loading 34 vol % than that of random distribution composites (1.81 W m^-1 K^-1 for epoxy/random 3D-BN composites, 1.16 W m^-1 K^-1 for epoxy/random BN composites) and exhibit a high glass transition temperature (178.9-229.2 °C) and dimensional stability (22.7 ppm/K). We attribute the increased thermal conductivity to the unique oriented 3D-BN thermally conducive network, in which the much higher thermal conductivity along the in-plane direction of BN microplatelets is most useful. This study paves the way for thermally conductive polymer composites used as thermal interface materials for next-generation electronic packaging and 3D integration circuits.

Harnessing Three Dimensional Anatomy of Graphene Foam to Induce Superior Damping in Hierarchical Polyimide Nanostructures

Graphene foam-based hierarchical polyimide composites with nanoengineered interface are fabricated in this study. Damping behavior of graphene foam is probed for the first time. Multiscale mechanisms contribute to highly impressive damping in graphene foam. Rippling, spring-like interlayer van der Waals interactions and flexing of graphene foam branches are believed to be responsible for damping at the intrinsic, interlayer and anatomical scales, respectively. Merely 1.5 wt% graphene foam addition to the polyimide matrix leads to as high as ≈300% improvement in loss tangent. Graphene nanoplatelets are employed to improve polymer-foam interfacial adhesion by arresting polymer shrinkage during imidization and π-π interactions between nanoplatelets and foam walls. As a result, damping behavior is further improved due to effective stress transfer from the polymer matrix to the foam. Thermo-oxidative stability of these nanocomposites is investigated by exposing the specimens to glass transition temperature of the polyimide (≈400 °C). The composites are found to retain their damping characteristics even after being subjected to such extreme temperature, attesting their suitability in high temperature structural applications. Their unique hierarchical nanostructure provides colossal opportunity to engineer and program material properties.

High-Density 3D-Boron Nitride and 3D-Graphene for High-Performance Nano-Thermal Interface Material

Compression studies on three-dimensional foam-like graphene and h-BN (3D-C and 3D-BN) revealed their high cross-plane thermal conductivity (62-86 W m^-1 K^-1) and excellent surface conformity, characteristics essential for thermal management needs. Comparative studies to state-of-the-art materials and other materials currently under research for heat dissipation revealed 3D-foam's improved performance (20-30% improved cooling, temperature decrease by ΔT of 44-24 °C).