Sub-critical gas-assisted processing using CO 2 foaming to enhance the exfoliation of graphene in polypropylene + graphene nanocomposites

The Study on the Morphology and Compression Properties of Microcellular TPU/Nanoclay Tissue Scaffolds for Potential Tissue Engineering Applications

Thermoplastic polyurethane (TPU) materials have shown promise in tissue engineering applications due to their mechanical properties and biocompatibility. However, the addition of nanoclays to TPU can further enhance its properties. In this study, the effects of nanoclays on the microstructure, mechanical behavior, cytocompatibility, and proliferation of TPU/nanoclay (TPUNC) composite scaffolds were comprehensively investigated. The dispersion morphology of nanoclays within the TPU matrix was examined using transmission electron microscopy (TEM). It was found that the nanoclays exhibited a well-dispersed and intercalated structure, which contributed to the improved mechanical properties of the TPUNC scaffolds. Mechanical testing revealed that the addition of nanoclays significantly enhanced the compressive strength and elastic resilience of the TPUNC scaffolds. Cell viability and proliferation assays were conducted using MG63 cells cultured on the TPUNC scaffolds. The incorporation of nanoclays did not adversely affect cell viability, as evidenced by the comparable cell numbers between nanoclay-filled and unfilled TPU scaffolds. The presence of nanoclays within the TPUNC scaffolds did not disrupt cell adhesion or proliferation. The incorporation of nanoclays improved the dispersion morphology, enhanced mechanical performance, and maintained excellent biocompatibility. These findings suggest that TPUNC composites have great potential for tissue engineering applications, providing a versatile and promising scaffold material for regenerative medicine.

Straightforward Strategy Toward In Situ Water-Phase Exfoliation and Improved Interfacial Adhesion to Fabricate High-Performance Polypropylene/Graphene Nanocomposites

Graphene is a potential candidate for achieving high-performance and multifunctional polypropylene (PP) composites. However, the complex manufacturing process and low dispersibility of graphene, as well as poor interfacial adhesion between graphene and polypropylene chains, stifle progress on large-scale production and applications of graphene/polypropylene composites. Here, we develop a strategy of maleic anhydride grafted polypropylene (MAPP) latex-assisted graphene exfoliation and melt blending to address the key challenges facing in industrial production. The surface property of the graphitic precursor is well-designed to achieve a high graphene exfoliation yield of ∼100% and induce abundant hydrogen bonding between the obtained mild-oxidized graphene (MOG) sheets and MAPP chains. Therefore, the MAPP-modified MOG can homogeneously disperse in the PP matrix and exhibits an excellent interfacial compatibility with the polymer. The addition of 5 wt % MOG results in simultaneous increase in the initial decomposition temperature, crystallization temperature, tensile strength, and Young's modulus by 43.2, 11.4 °C, 21.5, and 50.7%, respectively, and the electrical conductivity increases to 0.02 S·m-1. This work illustrates a practical solution to low-cost, eco-friendly, and feasible industrial production of graphene/PP composites through synchronous exfoliation and interfacial modification of graphene.

An Industrial Case for Polypropylene Nanocomposite Foams: Lightweight, Soundproof Exterior Automotive Parts

Lightweighting is a challenge for the automotive industry, and foaming is a key technology used to address this problem. A new practical approach is studied to regulate the cell formation of copolymer polypropylene (co-PP) by utilizing graphene nanoplatelets (xGnP) as a process aid during foam injection molding. The approach was designed to enable process freedom to tune part performance by adjusting the amount of xGnP masterbatch. Two different levels of 1–2 wt % xGnP and 0.25–0.35 wt % supercritical fluid (SCF) were investigated. Prepared samples were compared with samples prepared by the traditional method (twin-screw extrusion followed by foam injection molding). The nanocomposite with 2 wt % xGnP comparatively showed about twofold reduction in cell size magnitude. Although the increment in SCF amount resulted in a 47% and 122% enhancement in flexural modulus and strength, respectively, and a 45% loss in Izod unnotched impact strength, the cell size was prone to increasing with regard to low melt strength as compared to neat foams. In conclusion, a 12% weight reduction fulfilled the desired performance parameters in terms of mechanical and sound insulation by utilizing 2 wt % xGnP as a process aid.

Designer Core-Shell Nanoparticles as Polymer Foam Cell Nucleating Agents: The Impact of Molecularly Engineered Interfaces

The interface between nucleating agents and polymers plays a pivotal role in heterogeneous cell nucleation in polymer foaming. We describe how interfacial engineering of nucleating particles by polymer shells impacts cell nucleation efficiency in CO2 blown polymer foams. Core-shell nanoparticles (NPs) with a 80 nm silica core and various polymer shells including polystyrene (PS), poly(dimethylsiloxane) (PDMS), poly(methyl methacrylate) (PMMA), and poly(acrylonitrile) (PAN) are prepared and used as heterogeneous nucleation agents to obtain CO2 blown PMMA and PS micro- and nanocellular foams. Fourier transform infrared spectroscopy, thermogravimetric analysis, and transmission electron microscopy are employed to confirm the successful synthesis of core-shell NPs. The cell size and cell density are determined by scanning electron microscopy. Silica NPs grafted with a thin PDMS shell layer exhibit the highest nucleation efficiency values, followed by PAN. The nucleation efficiency of PS- and PMMA-grafted NPs are comparable with the untreated particles and are significantly lower when compared to PDMS and PAN shells. Molecular dynamics simulations (MDS) are employed to better understand CO2 absorption and nucleation, in particular to study the impact of interfacial properties and CO2-philicity. The MDS results show that the incompatibility between particle shell layers and the polymer matrix results in immiscibility at the interface area, which leads to a local accumulation of CO2 at the interfaces. Elevated CO2 concentrations at the interfaces combined with the high interfacial tension (caused by the immiscibility) induce an energetically favorable cell nucleation process. These findings emphasize the importance of interfacial effects on cell nucleation and provide guidance for designing new, highly efficient nucleation agents in nanocellular polymer foaming.

A Review of Wet Compounding of Cellulose Nanocomposites

Cellulose nanomaterials (CNs) are an emerging class of materials with numerous potential applications, including as additives or reinforcements for thermoplastics. Unfortunately, the preparation of CNs typically results in dilute, aqueous suspensions, and the lack of efficient water removal methods has hindered commercialization. However, water may also present opportunities for improving overall efficiencies if its potential is better understood and if it is better managed through the various stages of CN and composite production. Wet compounding represents one such possible opportunity by leveraging water's ability to aid in CN dispersion, act as a transport medium for metering and feeding of CNs, plasticize some polymers, or potentially facilitate the preparation of CNs during compounding. However, there are also considerable challenges and much investigation remains. Here, we review various wet compounding approaches used in the preparation of cellulose nanocomposites as well as the related concepts of wet feeding and wet extrusion fibrillation of cellulose. We also discuss potential opportunities, remaining challenges, and research and development needs with the ultimate goal of developing a more integrated approach to cellulose nanocomposite preparation and a more sophisticated understanding of water's role in the compounding process.

Insight into the Directional Thermal Transport of Hexagonal Boron Nitride Composites

Ideal dielectric materials for microelectronic devices should have high directionally tailored thermoconductivity with low dielectric constant and loss. Hexagonal boron nitride (hBN) with excellent thermal and dielectric properties shows a promise for the fabrication of thermoconductive dielectric polymer composites. Herein, a simple method for the fabrication of lightweight polymer/hBN composites with high directionally tailored thermoconductivity and excellent dielectric properties is presented. The solid polymer/hBN composites are manufactured by melt-compounding and injection molding. The porous composites are successfully manufactured in an injection molding process through supercritical fluid (SCF) foaming. X-ray tomography provides direct visualization of the internal microstructure and hBN orientation, leading to an in-depth understanding of the directionally dependent thermoconductivity of the polymer/hBN composite. Shear-induced orientation of hBN platelets in the solid HDPE/hBN composites leads to a significant anisotropic thermal conductivity. The solid HDPE/23.2 vol % hBN composites show an in-plane thermoconductivity as high as 10.1 W m^-1 K^-1, whereas the through-plane thermoconductivity is limited to 0.28 W m^-1 K^-1. However, the generation of a porous structure via SCF foaming imparts in situ exfoliation, random orientation, and interconnectivity of hBN platelets within the polymer matrix. This results in highly isotropic thermoconductivity with higher bulk thermal conductivity in the lightweight porous composites as compared to their solid counterparts. Furthermore, the electrically insulating composites developed in this study exhibit low dielectric constant and ultralow dielectric loss. Thus, this study presents a simple fabrication method to develop lightweight dielectric materials with tailored thermal conductivity for modern electronics.

Supercritical Fluid-Facilitated Exfoliation and Processing of 2D Materials

Since the first intercalation of layered silicates by using supercritical CO2 as a processing medium, considerable efforts have been dedicated to intercalating and exfoliating layered two-dimensional (2D) materials in various supercritical fluids (SCFs) to yield single- and few-layer nanosheets. Here, recent work in this area is highlighted. Motivating factors for enhancing exfoliation efficiency and product quality in SCFs, mechanisms for exfoliation and dispersion in SCFs, as well as general metrics applied to assess quality and processability of exfoliated 2D materials are critically discussed. Further, advances in formation and application of 2D material-based composites with assistance from SCFs are presented. These discussions address chemical transformations accompanying SCF processing such as doping, covalent surface modification, and heterostructure formation. Promising features, challenges, and routes to expanding SCF processing techniques are described.

Recent Trends of Foaming in Polymer Processing: A Review

Polymer foams have low density, good heat insulation, good sound insulation effects, high specific strength, and high corrosion resistance, and are widely used in civil and industrial applications. In this paper, the classification of polymer foams, principles of the foaming process, types of blowing agents, and raw materials of polymer foams are reviewed. The research progress of various foaming methods and the current problems and possible solutions are discussed in detail.

Evaluation of Exfoliated Graphite to Graphene in Polyamide 66 Using Novel High Shear Elongational Flow

Graphene has been publicized as the game changing material of this millennium. To this day, scalable production leading to exceptional material properties has been difficult to attain. Most methods require harsh chemicals, which result in destroying the graphene surface. A method was developed, exploiting high speed elongational flow in a novel designed batch mixer; creating a distribution of pristine few to many layer graphene flakes. The method focuses on exfoliating in a molten polyamide 66 (PA66) matrix, creating a graphene reinforced polymer matrix composite (G-PMC). The process revealed that high speed elongational flow was able to create few layer graphene. Graphite exfoliation was found driven in part by diffusion, leading to intercalation of PA66 in graphite. The intercalated structure lead to increases in the hydrogen bonding domain, creating anisotropic crystal domains. The thermal stability of the G-PMC was found to be dependent to the degree of exfoliation, PA66 crystal structure and composite morphology. The aim of this research is to characterize uniquely produced graphene containing polymer matrix composites using a newly created elongational flow field. Using elongational flow, graphite will be directly exfoliated into graphene within a molten polymer.

Enhanced Electrical and Electromagnetic Interference Shielding Properties of Polymer-Graphene Nanoplatelet Composites Fabricated via Supercritical-Fluid Treatment and Physical Foaming

Lightweight high-density polyethylene (HDPE)-graphene nanoplatelet (GnP) composite foams were fabricated via a supercritical-fluid (SCF) treatment and physical foaming in an injection-molding process. We demonstrated that the introduction of a microcellular structure can substantially increase the electrical conductivity and can decrease the percolation threshold of the polymer-GnP composites. The nanocomposite foams had a significantly higher electrical conductivity, a higher dielectric constant, a higher electromagnetic interference (EMI) shielding effectiveness (SE), and a lower percolation threshold compared to their regular injection-molded counterparts. The SCF treatment and foaming exfoliated the GnPs in situ during the fabrication process. This process also changed the GnP's flow-induced arrangement by reducing the melt viscosity and cellular growth. Moreover, the generation of a cellular structure rearranged the GnPs to be mainly perpendicular to the radial direction of the bubble growth. This enhanced the GnP's interconnectivity and produced a unique GnP arrangement around the cells. Therefore, the through-plane conductivity increased up to a maximum of 9 orders of magnitude and the percolation threshold decreased by up to 62%. The lightweight injection-molded nanocomposite foams of 9.8 vol % GnP exhibited a real permittivity of ε' = 106.4, which was superior to that of their regular injection-molded (ε' = 6.2). A maximum K-band EMI SE of 31.6 dB was achieved in HDPE-19 vol % GnP composite foams, which was 45% higher than that of the solid counterpart. In addition, the physical foaming reduced the density of the HDPE-GnP foams by up to 26%. Therefore, the fabricated polymer-GnP nanocomposite foams in this study pointed toward the further development of lightweight and conductive polymer-GnP composites with tailored properties.

Ultralight Microcellular Polymer-Graphene Nanoplatelet Foams with Enhanced Dielectric Performance

Dielectric polymer nanocomposites with high dielectric constant (ε') and low dielectric loss (tan δ) are extremely desirable in the electronics industry. Percolative polymer-graphene nanoplatelet (GnP) composites have shown great promise as dielectric materials for high-performance capacitors. Herein, an industrially-viable technique for manufacturing a new class of ultralight polymer composite foams using commercial GnPs with excellent dielectric performance is presented. Using this method, the high-density polyethylene (HDPE)-GnPs composites with a microcellular structure were fabricated by melt-mixing. This was followed by supercritical fluid (SCF) treatment and physical foaming in an extrusion process, which added an extra layer of design flexibility. The SCF treatment effectively in situ exfoliated the GnPs in the polymer matrix. Moreover, the generation of a microcellular structure produced numerous parallel-plate nanocapacitors consisting of GnP pairs as electrodes with insulating polymer as nanodielectrics. This significantly increased the real permittivity and decreased the dielectric loss. The ultralight extruded HDPE-1.08 vol % GnP composite foams, with a 0.15 g·cm^-3 density, had an excellent combination of dielectric properties (ε' = 77.5, tan δ = 0.003 at 1 × 10⁵ Hz), which were superior to their compression-molded counterparts (ε' = 19.9, tan δ = 0.15 and density of = 1.2 g·cm^-3) and to those reported in the literature. This dramatic improvement resulted from in situ GnP's exfoliation and dispersion, as well as a unique GnP parallel-plate arrangement around the cells. Thus, this facile method provides a scalable method to produce ultralight dielectric polymer nanocomposites, with a microscopically tailored microstructure for use in electronic devices.

Enhanced Thermal Conductivity of Graphene Nanoplatelet-Polymer Nanocomposites Fabricated via Supercritical Fluid-Assisted in Situ Exfoliation

As electronic devices become increasingly miniaturized, their thermal management becomes critical. Efficient heat dissipation guarantees their optimal performance and service life. Graphene nanoplatelets (GnPs) have excellent thermal properties that show promise for use in fabricating commercial polymer nanocomposites with high thermal conductivity. Herein, an industrially viable technique for manufacturing a new class of lightweight GnP-polymer nanocomposites with high thermal conductivity is presented. Using this method, GnP-high-density polyethylene (HDPE) nanocomposites with a microcellular structure are fabricated by melt mixing, which is followed by supercritical fluid (SCF) treatment and injection molding foaming, which adds an extra layer of design flexibility. Thus, the microstructure is tailored within the nanocomposites and this improves their thermal conductivity. Therefore, the SCF-treated HDPE 17.6 vol % GnP microcellular nanocomposites have a solid-phase thermal conductivity of 4.13 ± 0.12 W m^-1 K^-1. This value far exceeds that of their regular injection-molded counterparts (2.09 ± 0.03 W m^-1 K^-1) and those reported in the literature. This dramatic improvement results from in situ GnPs' exfoliation and dispersion, and from an elevated level of random orientation and interconnectivity. Thus, this technique provides a novel approach to the development of microscopically tailored structures for the production of lighter and more thermally conductive heat sinks for next generations of miniaturized electronic devices.

Improved Processability and the Processing-Structure-Properties Relationship of Ultra-High Molecular Weight Polyethylene via Supercritical Nitrogen and Carbon Dioxide in Injection Molding

The processability of injection molding ultra-high molecular weight polyethylene (UHMWPE) was improved by introducing supercritical nitrogen (scN₂) or supercritical carbon dioxide (scCO₂) into the polymer melt, which decreased its viscosity and injection pressure while reducing the risk of degradation. When using the special full-shot option of microcellular injection molding (MIM), it was found that the required injection pressure decreased by up to 30% and 35% when scCO₂ and scN₂ were used, respectively. The mechanical properties in terms of tensile strength, Young's modulus, and elongation-at-break of the supercritical fluid (SCF)-loaded samples were examined. The thermal and rheological properties of regular and SCF-loaded samples were analyzed using differential scanning calorimetry (DSC) and parallel-plate rheometry, respectively. The results showed that the temperature dependence of UHMWPE was very low, suggesting that increasing the processing temperature is not a viable method for reducing injection pressure or improving processability. Moreover, the use of scN₂ and scCO₂ with UHMWPE and MIM retained the high molecular weight, and thus the mechanical properties, of the polymer, while regular injection molding led to signs of degradation.