High-shear processing induced homogenous dispersion of pristine multiwalled carbon nanotubes in a thermoplastic elastomer

Effects of Orientation and Dispersion on Electrical Conductivity and Mechanical Properties of Carbon Nanotube/Polypropylene Composite

The orientation and dispersion of nanoparticles can greatly influence the conductivity and mechanical properties of nanocomposites. In this study, the Polypropylene/ Carbon Nanotubes (PP/CNTs) nanocomposites were produced using three different molding methods, i.e., compression molding (CM), conventional injection molding (IM), and interval injection molding (IntM). Various CNTs content and shear conditions give CNTs different dispersion and orientation states. Then, three electrical percolation thresholds (4 wt.% CM, 6 wt.% IM, and 9 wt.% IntM) were obtained by various CNTs dispersion and orientations. Agglomerate dispersion (Adis), agglomerate orientation (Aori), and molecular orientation (Mori) are used to quantify the CNTs dispersion and orientation degree. IntM uses high shear to break the agglomerates and promote the Aori, Mori, and Adis. Large Aori and Mori can create a path along the flow direction, which lead to an electrical anisotropy of nearly six orders of magnitude in the flow and transverse direction. On the other hand, when CM and IM samples already build the conductive network, IntM can triple the Adis and destroy the network. Moreover, mechanical properties are also been discussed, such as the increase in tensile strength with Aori and Mori but showing independence with Adis. This paper proves that the high dispersion of CNTs agglomerate goes against forming a conductivity network. At the same time, the increased orientation of CNTs causes the electric current to flow only in the orientation direction. It helps to prepare PP/CNTs nanocomposites on demand by understanding the influence of CNTs dispersion and orientation on mechanical and electrical properties.

Construction and application of carbon aerogels in microwave absorption

Electromagnetic pollution that threatens human health, the ecological environment and electronic equipment has been recognized as a serious environmental issue. In view of this, microwave absorbing materials (MAMs) are urgently required in modern society. Compared with traditional MAMs, carbon aerogels have inherent advantages in microwave absorption because of their high porosity and controllable conductive networks. Moreover, they are self-supporting 3D architectures with tailorable shapes, which satisfy most application scenarios. Therefore, carbon aerogels have aroused great interest in recent years and are being developed as promising absorption materials. In this review, we emphasize recent developments in carbon-aerogel-based MAMs constructed with some typical carbon nanomaterials, including graphene, carbon nanotubes and pyrolytic carbon. Their preparation methods, especially some newly developed strategies, are introduced as well as their influence on the structures and properties of aerogels. With a brief analysis of classic microwave absorption processes, we propose the requirements and strategies for modifying carbon aerogels to achieve ideal microwave absorption performance. Finally, we provide comprehensive comparisons of the MA performances of various carbon aerogels that show application potential and set forth the challenges and prospects of this kind of MAM.

Improving Thermal Conductivity of Injection Molded Polycarbonate/Boron Nitride Composites by Incorporating Spherical Alumina Particles: The Influence of Alumina Particle Size

In this work, the influences of alumina (Al₂O₃) particle size and loading concentration on the properties of injection molded polycarbonate (PC)/boron nitride (BN)/Al₂O₃ composites were systematically studied. Results indicated that both in-plane and through-plane thermal conductivity of the ternary composites were significantly improved with the addition of spherical Al₂O₃ particles. In addition, the thermal conductivity of polymer composites increased significantly with increasing Al₂O₃ concentration and particle size, which were related to the following factors: (1) the presence of spherical Al₂O₃ particles altered the orientation state of flaky BN fillers that were in close proximity to Al₂O₃ particles (as confirmed by SEM observations and XRD analysis), which was believed crucial to improving the through-plane thermal conductivity of injection molded samples; (2) the presence of Al₂O₃ particles increased the filler packing density by bridging the uniformly distributed BN fillers within PC substrate, thereby leading to a significant enhancement of thermal conductivity. The in-plane and through-plane thermal conductivity of PC/50 μm-Al₂O₃ 40 wt%/BN 20 wt% composites reached as high as 2.95 and 1.78 W/mK, which were 1183% and 710% higher than those of pure PC, respectively. The prepared polymer composites exhibited reasonable mechanical performance, and excellent electrical insulation properties and processability, which showed potential applications in advanced engineering fields that require both thermal conduction and electrical insulation properties.

Geometric percolation of hard-sphere dispersions in shear flow

We combine a heuristic theory of geometric percolation and the Smoluchowski theory of colloid dynamics to predict the impact of shear flow on the percolation threshold of hard spherical colloidal particles, and verify our findings by means of molecular dynamics simulations. It appears that the impact of shear flow is subtle and highly non-trivial, even in the absence of hydrodynamic interactions between the particles. The presence of shear flow can both increase and decrease the percolation threshold, depending on the criterion used for determining whether or not two particles are connected and on the Péclet number. Our approach opens up a route to quantitatively predict the percolation threshold in nanocomposite materials that, as a rule, are produced under non-equilibrium conditions, making comparison with equilibrium percolation theory tenuous. Our theory can be adapted straightforwardly for application in other types of flow field, and particles of different shape or interacting via other than hard-core potentials.

Controlled Degradation of Commercial Resin for Meltblown Nonwoven Fabric Sheet Production

Manufacturing meltblown nonwoven fabrics requires special grades of resin with very low viscosity, which are not dealt with so much on market and cost quite high compared to the standard grades. We propose a high-shear rate processing method that can quickly and easily produce such low-viscosity resin from the commercial one without using organic peroxides. In this method, we apply high-shear stress to molten resin by using a high-shear extruder, which is a single screw extruder with high screw rotation speed, and the resin is thermally decomposed of its shear-induced heat which is quickly generated. We found that polypropylene with a value of melt flow rate over a thousand, which was required for the meltblown process, was produced from the standard grade with the high-shear extruder at the screw rotation speed of 3600 min−1 and the barrel temperature over 300 ∘C. Using the degradated polypropylene, a meltblown nonwoven fabric sheet was successfully fabricated. We also developed a numerical simulator of the high-shear extruder which can handle a wide range of the screw rotation speed and barrel temperature by the Nusselt number modulated with the operational conditions. The experimental values of the zero-shear viscosity and temperature at the exit of the extruder agreed well with the simulation results. Our high-shear rate processing method will enable us to quickly and easily produce various meltblown nonwoven fabric sheets at low costs.

Morphological Structure, Rheological Behavior, Mechanical Properties and Sound Insulation Performance of Thermoplastic Rubber Composites Reinforced by Different Inorganic Fillers

The application area of a sound insulation material is highly dependent on the technology adopted for its processing. In this study, thermoplastic rubber (TPR, polypropylene/ethylene propylene diene monomer) composites were simply prepared via an extrusion method. Two microscale particles, CaCO₃ and hollow glass microspheres (HGW) were chosen to not only enhance the sound insulation but also reinforced the mechanical properties. Meanwhile, the processing capability of composites was confirmed. SEM images showed that the CaCO₃ was uniformly dispersed in TPR matrix with ~3 μm scale aggregates, while the HGM was slightly aggregated to ~13 μm scale. The heterogeneous dispersion of micro-scale fillers strongly affected the sound transmission loss (STL) value of composites. The STL values of TPR composites with 40 wt % CaCO₃ and 20 wt % HGM composites were about 12 dB and 7 dB higher than that of pure TPR sample, respectively. The improved sound insulation performances of the composites have been attributed to the enhanced reflection and dissipate sound energy in the heterogeneous composite. Moreover, the mechanical properties were also enhanced. The discontinued sound impedance and reinforced stiffness were considered as crucial for the sound insulation.

High Shear Processing of (PP/EPR)/Silica Nanocomposites: Improvement of Morphology and Properties

The aim of this article is to upgrade the performance of polypropylene/ethylene propylene rubber (PP/EPR) blends by addition of hydrophobic nanosilica (SiR805) and using “high shear processing technology”. The morphological developments, mechanical and rheological properties of these composites were investigated as a function of processing conditions. High shear processing has proved to be an efficient process to decrease the size of the dispersed phase (EPR) up to 300 nm and to disperse finely nanosilica particles to less than 30 nm especially at 800 min−1. Moreover, the morphology stability of the nanocomposite is ascribed to the formation of a core shell structure (EPR nodules = core; nano-silica = shell) and selective location of nanosilica at the interface. More importantly, this core-shell structure is favoured to enhance the impact strength of the (PP/EPR)/3 wt% SiR805 nanocomposite. In agreement to the obtained morphology, the improvement (about 60 %) of elongation at break attests a good adhesion between phases due to high shear effect as highlighted by viscoelastic properties. Therefore, high shear processing technology has proved to be a relevant method to prepare nanocomposites with high performances without adding any additive and offers new perspectives for recycling and lightening structures.