Green Preparation of Expandable Graphite and Its Application in Flame-Resistance Polymer Elastomer

Sequential Effect of Dual-Layered Hybrid Graphite Anodes on Electrode Utilization During Fast-Charging Li-Ion Batteries

To recharge lithium-ion batteries quickly and safely while avoiding capacity loss and safety risks, a novel electrode design that minimizes cell polarization at a higher current is highly desired. This work presents a dual-layer electrode (DLE) technology via sequential coating of two different anode materials to minimize the overall electrode resistance upon fast charging. Electrochemical impedance spectroscopy and distribution of relaxation times analysis revealed the dynamic evolution of electrode impedances in synthetic graphite (SG) upon a change in the state of charge (SOC), whereas the natural graphite (NG) maintains its original impedance regardless of SOC variation. This disparity dictates the sequence of the NG and SG coating layers within the DLE, considering the temporal SOC gradient developed upon fast charging. Simulation and experimental results suggest that DLE positioning NG and SG on the top (second-layer) and bottom (first-layer), respectively, can effectively reduce the overall resistance at a 4 C-rate (15-min charging), demonstrating two times higher capacity retention (61.0%) over 200 cycles than its counterpart with reversal sequential coating, and is higher than single-layer electrodes using NG or NG/SG binary mixtures. Hence, this study can guide the combinatorial sequence for multi-layer coating of various active materials for a lower-resistivity, thick-electrode design.

The potential of thermally expanded graphite in oil sorption applications

An oil spill occurs when liquid petroleum hydrocarbons are released into the environment, whether accidentally or intentionally, in substantial quantities. The impact of an oil spill on the ecosystem is significant and should not be underestimated. Various techniques are employed to address oil spills, including mechanical, physical, biological, and physicochemical methods. Among these techniques, adsorption is considered the most suitable approach. Adsorption is promising due to its simplicity, ease of use, high removal capacity, and rapid pollutant removal. An excellent adsorbent material exhibits unique characteristics that enhance its efficacy in liquid adsorption. Sorbents are categorized into synthetic and natural types. Porous carbon materials, especially expanded graphite, are widely utilized in wastewater treatment due to their micropores and exceptional adsorption capacity. The distinctive properties of expanded graphite, including its low density, high porosity, and electrical conductivity, have garnered significant global attention for various potential applications. In essence, expanded graphite offers a powerful and practical approach to oil spill cleanup due to its efficient oil adsorption, selective targeting, ease of use, and potential reusability. This review article summarizes the preparation techniques, structure, and properties of expanded graphite. It also delves into recent advancements in using expanded graphite for oil spill cleanup. The article concludes by outlining potential future directions in this field and discussing the commercial viability of some of these techniques.

Functionalized Halloysite Nanotubes as Potential Drug Carriers

The aim of the work was to examine the possibility of using modified halloysite nanotubes as a gentamicin carrier and to determine the usefulness of the modification in terms of the effect on the amount of the drug attached, its release time, but also on the biocidal properties of the carriers. In order to fully examine the halloysite in terms of the possibility of gentamicin incorporating, a number of modifications of the native halloysite were carried out prior to gentamicin intercalation with the use of sodium alkali, sulfuric and phosphoric acids, curcumin and the process of delamination of nanotubes (expanded halloysite) with ammonium persulfate in sulfuric acid. Gentamicin was added to unmodified and modified halloysite in an amount corresponding to the cation exchange capacity of pure halloysite from the Polish Dunino deposit, which was the reference sample for all modified carriers. The obtained materials were tested to determine the effect of surface modification and their interaction with the introduced antibiotic on the biological activity of the carrier, kinetics of drug release, as well as on the antibacterial activity against Escherichia coli Gram-negative bacteria (reference strain). For all materials, structural changes were examined using infrared spectroscopy (FTIR) and X-ray diffraction (XRD); thermal differential scanning calorimetry with thermogravimetric analysis (DSC/TG) was performed as well. The samples were also observed for morphological changes after modification and drug activation by transmission electron microscopy (TEM). The conducted tests clearly show that all samples of halloysite intercalated with gentamicin showed high antibacterial activity, with the highest antibacterial activity for the sample modified with sodium hydroxide and intercalated with the drug. It was found that the type of halloysite surface modification has a significant effect on the amount of gentamicin intercalated and then released into the surrounding environment but does not significantly affect its ability to further influence drug release over time. The highest amount of drug released among all intercalated samples was recorded for halloysite modified with ammonium persulfate (real loading efficiency above 11%), for which high antibacterial activity was found after surface modification, before drug intercalation. It is also worth noting that intrinsic antibacterial activity was found for non-drug-intercalated materials after surface functionalization with phosphoric acid (V) and ammonium persulfate in the presence of sulfuric acid (V).

Large Enhancement in Thermal Conductivity of Solvent-Cast Expanded Graphite/Polyetherimide Composites

We demonstrate in this work that expanded graphite (EG) can lead to a very large enhancement in thermal conductivity of polyetherimide−graphene and epoxy−graphene nanocomposites prepared via solvent casting technique. A k value of 6.6 W⋅m⁻¹⋅K⁻¹ is achieved for 10 wt% composition sample, representing an enhancement of ~2770% over pristine polyetherimide (k~0.23 W⋅m⁻¹⋅K⁻¹). This extraordinary enhancement in thermal conductivity is shown to be due to a network of continuous graphene sheets over long−length scales, resulting in low thermal contact resistance at bends/turns due to the graphene sheets being covalently bonded at such junctions. Solvent casting offers the advantage of preserving the porous structure of expanded graphite in the composite, resulting in the above highly thermally conductive interpenetrating network of graphene and polymer. Solvent casting also does not break down the expanded graphite particles due to minimal forces involved, allowing for efficient heat transfer over long−length scales, further enhancing overall composite thermal conductivity. Comparisons with a recently introduced effective medium model show a very high value of predicted particle–particle interfacial conductance, providing evidence for efficient interfacial thermal transport in expanded graphite composites. Field emission environmental scanning electron microscopy (FE−ESEM) is used to provide a detailed understanding of the interpenetrating graphene−polymer structure in the expanded graphite composite. These results open up novel avenues for achieving high thermal conductivity polymer composites.

Effect of expansion temperature on the properties of expanded graphite and modified linear low density polyethylene

To study the influence of expansion temperature on the properties of expanded graphite (EBG), EBG300, EBG600, and EBG900 were prepared by heating expandable graphite (EG) at 300, 600, and 900 °C, respectively. Furthermore, the influence of these EBGs on the combustion performance and physical-mechanical properties of linear low density polyethylene (LLDPE) were investigated. The expansion volumes of EBG300, EBG600, and EBG900 increase with the rise of temperature, and a four-stage ordered structure of “graphite worm” gradually forms. The thermal stability increases gradually for EBG300, EBG600, and EBG900. On the contrary, the thermal conductivity decreases in sequence. However, the incorporation of EBG900 promotes the formation of a continuous network structure and makes the modified LLDPE to present the best heat transmission. The addition of 30 wt% of these EBGs significantly improves LLDPE’s flame retardancy and high-temperature thermal stability. The total heat release, the peak value of heat release rate, and the fire growth index of 70LLDPE/30EBG300 reduce by 69, 91, and 87% respectively, while the effective fire performance index improves seven times. The addition of these additives reduces the tensile strength and elongation at break, the larger the EBG size, the more obvious the effect.

Highly Porous Expanded Graphite: Thermal Shock vs. Programmable Heating

Highly porous expanded graphite was synthesized by the programmable heating technique using heating with a constant rate (20 °C/min) from room temperature to 400–700 °C. The samples obtained were analyzed by scanning electron microscopy, energy-dispersive spectroscopy, low-temperature nitrogen adsorption, X-ray photoelectron spectroscopy, Raman spectroscopy, thermogravimetry, and differential scanning calorimetry. A comparison between programmable heating and thermal shock as methods of producing expanded graphite showed efficiency of the first one at a temperature 400 °C, and the surface area reached 699 and 184 m²/g, respectively. The proposed technique made it possible to obtain a relatively higher yield of expanded graphite (78–90%) from intercalated graphite. The experiments showed the advantages of programmable heating in terms of its flexibility and the possibility to manage the textural properties, yield, disorder degree, and bulk density of expanded graphite.

Microwave-treated Expandable Graphite Granule for Enhancing the Bioelectricity Generation of Microbial Fuel Cells

Microbial fuel cells (MFCs) convert chemical energy to electrical energy via electrochemically active microorganisms. The interactions between microbes and the surface of a carbon electrode play a vital role in capturing the respiratory electrons from bacteria. Therefore, improvements in the electrochemical and physicochemical properties of carbon materials are essential for increasing performance. In this study, a microwave and sulfuric acid treatment was used to modify the surface structure of graphite granules. The prepared expandable graphite granules (EGG) exhibited a 1.5 times higher power density than the unmodified graphite granules (1400 vs. 900 mW/m3). Scanning electron microscopy and Fourier transform infrared spectroscopy revealed improved physical and chemical characteristics of the EGG surface. These results suggest that physical and chemical surface modification using sulfuric acid and microwave heating improves the performance of electrode-based bioprocesses, such as MFCs.

Expandable Graphite for Flame Retardant PA6 Applications

A new expandable graphite (EG) type was studied as a flame retardant additive in Polyamide 6 (PA6). The fire behavior was characterized by a cone calorimeter using external heat fluxes of 35, 50 and 65 kW/m², limiting the oxygen index (LOI) and UL-94 burning tests. Additionally, electric and thermal conductivity as well as rheological properties were characterized to provide a general property overview. Fire tests were conducted using dry and humid conditioned samples. Cone Calorimeter tests showed a minimum filling degree of 15 wt.% (8.6 vol.%) EG was required to achieve a significant fire inhibiting effect in PA6 independent of the sample condition. UL-94 fire tests show a V0 classification at filling degrees greater than 20 wt.% (humid) and 25 wt.% (dry), although the associated LOI values of 39% and 38% demonstrate good flammability inhibition. Correlation analyses were conducted to identify major influences given by the sample condition for most important key figures measured in cone calorimeter tests. Accordingly, humid-conditioned samples containing between 2.5 (PA6 + 25 wt.% EG) and 4.2 wt.% (PA6) water were found to reduce the total heat evolved (THE) on average by 16% and the total smoke production (TSP) on average by 22%.

Expanded Polystyrene Beads Coated with Intumescent Flame Retardant Material to Achieve Fire Safety Standards

The compatibility and coating ratio between flame retardant materials and expanded polystyrene (EPS) foam is a major impediment to achieving satisfactory flame retardant performance. In this study, we prepared a water-based intumescent flame retardant system and methylene diphenyl diisocyanate (MDI)-coated expandable polystyrene microspheres by a simple coating approach. We investigated the compatibility, coating ratio, and fire performance of EPS- and MDI-coated EPS foam using a water-based intumescent flame retardant system. The microscopic study revealed that the water-based intumescent flame retardant materials were successfully incorporated with and without MDI-coated EPS microspheres. The cone calorimeter tests (CCTs) of the MDI-coated EPS containing water-based intumescent flame retardant materials exhibited better flame retardant performance with a lower total heat release (THR) 7.3 MJ/m2, peak heat release rate (PHRR) 57.6 kW/m2, fire growth rate (FIGRA) 2027.067 W/m2.s, and total smoke production (TSP) 0.133 m2. Our results demonstrated that the MDI-coated EPS containing water-based intumescent flame retardant materials achieved flame retarding properties as per fire safety standards.

Hybrid Structures Made of Polyurethane/Graphene Nanocomposite Foams Embedded within Aluminum Open-Cell Foam

This paper focuses on the development of hybrid structures containing two different classes of porous materials, nanocomposite foams made of polyurethane combined with graphene-based materials, and aluminum open-cell foams (Al-OC). Prior to the hybrid structures preparation, the nanocomposite foam formulation was optimized. The optimization consisted of studying the effect of the addition of graphene oxide (GO) and graphene nanoplatelets (GNPs) at different loadings (1.0, 2.5 and 5.0 wt%) during the polyurethane foam (PUF) formation, and their effect on the final nanocomposite properties. Globally, the results showed enhanced mechanical, acoustic and fire-retardant properties of the PUF nanocomposites when compared with pristine PUF. In a later step, the hybrid structure was prepared by embedding the Al-OC foam with the optimized nanocomposite formulation (prepared with 2.5 wt% of GNPs (PUF/GNPs2.5)). The process of filling the pores of the Al-OC was successfully achieved, with the resulting hybrid structure retaining low thermal conductivity values, around 0.038 W∙m−1∙K−1, and presenting an improved sound absorption coefficient, especially for mid to high frequencies, with respect to the individual foams. Furthermore, the new hybrid structure also displayed better mechanical properties (the stress corresponding to 10% of deformation was improved in more than 10 and 1.3 times comparatively to PUF/GNPs2.5 and Al-OC, respectively).

Photophysical deactivation behaviour of Rhodamine B using different graphite materials

In the present work, an attempt has been made to elucidate the structural features of synthesized graphite materials, i.e., expanded graphite (EG) and an expanded graphite/silver nanoparticles (EG/AgNPs) nanocomposite. In order to obtain knowledge about the functional groups present, the interlayer spacing between the carbon layers, topographical features, and the characterization of the materials were carried out using Fourier-transformer infrared spectroscopy, X-ray diffraction, Raman spectroscopy, field emission scanning electron microscopy-energy dispersive X-ray spectroscopy and atomic force microscope. Furthermore, the quenching efficiency of the synthesized graphite materials was also compared using Rhodamine B (Rhd B) as a fluorescent probe. The non-linear behaviour of the Stern–Volmer plots suggested that the complex quenching mechanism (a combination of static and dynamic quenching) was responsible for the decrease in photoluminescence intensity. At a lower concentration of the quencher, the static quenching mechanism was dominant whereas at a higher concentration dynamic processes seemed to be more likely. The binding strength of the complexation between the fluorophore and the quencher at lower concentrations was studied in detail for both of the synthesized materials. The analysis showed that the EG/AgNPs exhibited better quenching efficiency and possessed a strong binding strength in comparison to EG. The thermodynamic parameters of this association suggested that the interaction process was spontaneous and exothermic in nature. Thus, this work offers helpful insights into the fluorescence quenching mechanisms of the Rhd B/EG and its composite system.

Graphical representation of varying quenching mechanism of RhD B dye using different graphite materials i.e. EG and EG/AgNPs.

The Preparation and Characterization of MnFe2O4-Decorated Expanded Graphite for Removal of Heavy Oils from Water

Recently, many methods have been developed to efficiently eliminate oil spills due to its long-term harmful effects on marine life and human health. Expanded graphite (EG) has been considered as an excellent platform to remove contaminated oil from aqueous solution through a facile adsorption route. As an innovative approach, the decoration of magnetic components, namely, MnFe₂O₄, into graphite layers was taken into account for facilitating phase separation under magnetic field which resulted into an easy collection of the used adsorbents in a large scale. The expanded graphite/manganese ferrite composites were prepared from Vietnamese graphite flakes via a two-stage process. Characterization was performed using Scanning Electron Microscope (SEM), Fourier-Transform Infrared Spectroscopy (FTIR), X-Ray Powder Diffraction (XRD), Vibrating Sample Magnetometer (VSM), Energy-Dispersive X-ray (EDS), and nitrogen adsorption/desorption analysis. The adsorption behavior of EG-MnFe₂O₄ for widespread used heavy oils, including diesel oil and crude oil, was investigated under the effects of adsorption conditions, i.e., contact time, loaded oil dosage, and salinity of mixing oil and water. The obtained results showed successful incorporation of MnFe₂O₄ into graphite sheets and no considerable change on the worm-like structure of EG. The results also showed that incorporated manganese ferrites enhanced the magnetism EG up to 16 emu/g, which made the recovery of used adsorbent conveniently. The EG-MnFe₂O₄ adsorbents exhibited the strong adsorption ability toward diesel oil (32.20 ± 0.46 g DO/g EG) and crude oil (33.07 ± 0.33 g CO/g EG). In brief, EG-MnFe₂O₄ material provides a potential and promising platform with high performance for oil spill removal.

Enhancing Flame Retardancy, Thermal Stability, Physical and Mechanical Properties of Polyethylene Foam with Polyphosphate Modified Expandable Graphite and Ammonium Polyphosphate

The method of preparing polyolefin foam with good flame retardancy, thermal stability, and physical and mechanical properties was investigated. Foaming condition of linear low density polyethylene (LLDPE) was investigated with triphenyl phosphate (TPP) as plasticizer, NaHCO3 as foaming agent. The influence of modified expandable graphite (EGP) and ammonium polyphosphate (II) on foam density, compression strength, combustion characteristics and thermal stability was explored. Results verified that EGP presented better dilatability and flame retardancy than the normal expandable graphite. Addition of EGp improved the limiting oxygen index (LOI) of 15NaHCO3/100 LLDPETPP/30EGp foam from 18.8% to 24.6%. Furthermore, the combination of EGp and ammonium polyphosphate (II) (APP) at the mass ratio of 2:1 improved the LOI of 15NaHCO3/100 LLDPETPP/20EGp/10APP sample to 27.9%, and the vertical burning UL-94 level reached V-0, indicating that this material was flame retardant. Although these additives made 15NaHCO3/100 LLDPETPP/20EGp/10APP composite exhibit a high density of 142.5 kg m−3, which was increased by 12.3 wt% relative to the 15NaHCO3/100 LLDPETPP foam, it could improve the compressive strength to 0.4747 MPa, which was about 2.7 times that of the matrix. The thermal stability of the material was also enhanced.

Simultaneously enhanced mechanical properties and flame retardancy of UHMWPE with polydopamine-coated expandable graphite

The potential prospect of expandable graphite (EG) in the development of polymer composites is severely limited by required large additions and poor interface compatibility with the polymer.

Polyurethane Foams: Past, Present, and Future

Polymeric foams can be found virtually everywhere due to their advantageous properties compared with counterparts materials. Possibly the most important class of polymeric foams are polyurethane foams (PUFs), as their low density and thermal conductivity combined with their interesting mechanical properties make them excellent thermal and sound insulators, as well as structural and comfort materials. Despite the broad range of applications, the production of PUFs is still highly petroleum-dependent, so this industry must adapt to ever more strict regulations and rigorous consumers. In that sense, the well-established raw materials and process technologies can face a turning point in the near future, due to the need of using renewable raw materials and new process technologies, such as three-dimensional (3D) printing. In this work, the fundamental aspects of the production of PUFs are reviewed, the new challenges that the PUFs industry are expected to confront regarding process methodologies in the near future are outlined, and some alternatives are also presented. Then, the strategies for the improvement of PUFs sustainability, including recycling, and the enhancement of their properties are discussed.

Establishment of a highly efficient flame-retardant system for rigid polyurethane foams based on bi-phase flame-retardant actions

Rigid polyurethane foam (PU), one of the most promising wall insulation materials, exhibits high flammability and fire risk. In this work, PU/EG/HQ composites with highly effective flame retardancy were fabricated by adding two kinds of flame retardants, expandable graphite (EG) and 10-(2,5-dihydroxyphenyl)-10-hydro-9-oxa-10-phosphorylphenanthrene-10-oxide (DOPO-HQ), during the synthesis of polyurethane. Thermal stability and flammability were evaluated using the limiting oxygen index (LOI), thermogravimetric analysis (TGA), UL-94 vertical flame results, and cone colorimeter tests. The as-synthesized PU/EG/HQ composites showed a high LOI value, a maximum peak heat release rate (PHRR) value which was decreased by 58.5% and an increased char yield at 800 °C. They also achieved UL-94 V-0 classification. SEM and Raman spectra indicated that the “worm-like” intumescent char layer with a graphitized structure and the formed viscous liquid film were vital factors in the enhancement of the flame retardancy of polyurethane foam in the condensed phase. TG-IR results show that the release of toxic volatiles and flammable gases from the PU/EG/HQ samples was remarkably decreased compared with the release from pure PU. This work associates a gas–solid biphase flame retardancy mechanism with the incorporation of two types of flame retardant and presents an effective method for the synthesis of bi-phase flame-retardant polymers.

The combination of EG and HQ has been found to endow a PU matrix with excellent gas–solid bi-phase flame retardancy.