Highly Oriented Graphite Aerogel Fabricated by Confined Liquid-Phase Expansion for Anisotropically Thermally Conductive Epoxy Composites

Effects of expanded graphite's structural and elemental characteristics on its oil and heavy metal sorption properties

Expanded graphite has promising potential environmental applications due to its porous structure and oleophilic nature, which allow it to absorb large quantities of oil. The material is produced by intercalating graphite and applying heat to convert the intercalant into gas to cause expansion between the layers in the graphite. Using different intercalants and temperature conditions results in varying properties of expanded graphite. This work has proven that the sorption properties of commercial expanded graphite differ significantly due to the material's structural and elemental characteristics, which can be attributed to the intercalation method. This resulted in various degrees of exfoliation of the graphite and possible functionalisation of the graphene sheets within the structure. This affected the material's sorption capacity and its affinity for heavy metal sorption by incorporating selectivity towards the sorption of certain metals. It was found that sample EG3, which underwent a less harsh expansion, exhibited lower porosity than EG1, and thus, the sample absorbed less oil at 37.29 g/g compared to the more expanded samples EG1 and EG2 with 55.16 g/g and 48.82 g/g, respectively. However, it was able to entrap a wider variety of metal particles compared to EG1 and EG2, possibly due to its smaller cavities allowing for a capillary effect between the graphene sheets and greater Van der Waals forces. A second possibility is that ionic or coordination complexes could form with certain metals due to the possible functionalisation of the expanded graphite during the intercalation process. This would be in addition to coordination between the metals and expanded graphite carbon atoms. The findings suggest that there is evidence of functionalisation as determined by XRD and elemental analyses. However, further investigation is necessary to confirm this hypothesis. The findings in this work suggest that the first mechanism of sorption was more likely to be related to the degree of expansion of the expanded graphite. Various metals are present in used oil, and their removal can be challenging. Some metals in oil are not considered heavy since they have a relatively low density but can be associated with heavy metals in terms of toxicity.

Tetris-Style Stacking Process to Tailor the Orientation of Carbon Fiber Scaffolds for Efficient Heat Dissipation

As the miniaturization of electronic devices and complication of electronic packaging, there are growing demands for thermal interfacial materials with enhanced thermal conductivity and the capability to direct the heat toward heat sink for highly efficient heat dissipation. Pitch-based carbon fiber (CF) with ultrahigh axial thermal conductivity and aspect ratios exhibits great potential for developing thermally conductive composites as TIMs. However, it is still hard to fabricate composites with aligned carbon fiber in a general approach to fully utilize its excellent axial thermal conductivity in specific direction. Here, three types of CF scaffolds with different oriented structure were developed via magnetic field-assisted Tetris-style stacking and carbonization process. By regulating the magnetic field direction and initial stacking density, the self-supporting CF scaffolds with horizontally aligned (HCS), diagonally aligned and vertically aligned (VCS) fibers were constructed. After embedding the polydimethylsiloxane (PDMS), the three composites exhibited unique heat transfer properties, and the HCS/PDMS and VCS/PDMS composites presented a high thermal conductivity of 42.18 and 45.01 W m-1 K-1 in fiber alignment direction, respectively, which were about 209 and 224 times higher than that of PDMS. The excellent thermal conductivity is mainly ascribed that the oriented CF scaffolds construct effective phonon transport pathway in the matrix. In addition, fishbone-shaped CF scaffold was also produced by multiple stacking and carbonization process, and the prepared composites exhibited a controlled heat transfer path, which can allow more versatility in the design of thermal management system.

Vertical Array of Graphite Oxide Liquid Crystal by Microwire Shearing for Highly Thermally Conductive Composites

Excellent through-plane thermally conductive composites are highly demanded for efficient heat dissipation. Giant sheets have large crystalline domain and significantly reduce interface phonon scattering, making them promising to build highly thermally conductive composites. However, realizing vertical orientation of giant sheets remains challenging due to their enormous mass and huge hydrodynamic drag force. Here, we achieve highly vertically ordered liquid crystals of giant graphite oxide (more than 100 µm in lateral dimension) by microwire shearing, which endows the composite with a recorded through-plane thermal conductivity of 94 W m^-1 K^-1 . Microscale shearing fields induced by vertical motion of microwires conquer huge hydrodynamic energy barrier and vertically reorient giant sheets. The resulting liquid crystals exhibit extremely retarded relaxation and impart large-scale vertical array with bidirectional ordering degree as high as 0.82. The graphite array-based composites demonstrate an ultrahigh thermal enhancement efficiency of over 35 times per unit volume. Furthermore, the composites improve cooling efficiency by 93% for thermal management tests compared to commercial thermal interface materials. This work offers a novel methodology to precisely manipulate the orientation of giant particles and promote large-scale fabrication of vertical array with advanced functionalities.

Synthesis and adsorption performance of three-dimensional gels assembled by carbon nanomaterials for heavy metal removal from water: A review

This review focuses on the removal of heavy metals from water by three-dimensional gels with carbon nanomaterials as the main building units. It highlights the fundamental knowledge, most recent advances, and future prospects of carbon nanomaterial-assembled gels (CNAGs) as effective adsorbents for heavy metals in water. Various synthesis methods of CNAGs including template-assisted, self-assembly and other methods are systematically summarized and evaluated. Adsorption performances of CNAGs to typical cationic and anionic heavy metals, especially lead, cadmium, mercury, chromium, and arsenic, are thoroughly examined and discussed in detail. These analyses bring out that composite CNAGs constructed from carbon nanomaterials with polymers or other engineered nanoparticles are the most promising adsorbents for heavy metal removal from water. Current challenges and future research directions that are critical to the applications of CNAGs in the removal of heavy metals from contaminated water are outlined at the end of the review.

Hyperbolic Graphene Framework with Optimum Efficiency for Conductive Composites

Constructing conductive filler networks with high efficiency is essential to fabricating functional polymer composites. Although two-dimensional (2D) sheets have prevailed in nanocomposites, their efficiency in enhancing conductive functions seems to reach a limit, as if merely addressing the dispersion homogeneity. Here, we exploit the unrecognized geometric curvature of 2D sheets to break the efficiency limit of filler systems. We introduce the hyperbolic curvature concept to mediate the incompatibility between 2D planar topology and 3D filler space and hold the efficient conductive path through face-to-face contact. The hyperbolic graphene framework exhibits a record efficiency in enhancing electrically and thermally conductive functions of nanocomposites. At a volume loading of only 1.6%, the thermal and electrical conductivities reach 31.6 W/(mK) and 13 911 S/m, respectively. We demonstrate that the conductive nanocomposites with a hyperbolic graphene aerogel framework are useful for thermal management, sensing, and electromagnetic shielding. Our work provides a solution to reconcile the incompatibility between the 2D planar structure of sheets and the highly expected 3D conductive path, presenting a geometrically optimal filler system to break the efficiency limit of multifunctional nanocomposites and broaden the structural design space of 2D sheets by curvature modulation to meet more applications.

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.

Wood-Derived Composites with High Performance for Thermal Management Applications

Fabricating advanced polymer composites with remarkable mechanical and thermal conductivity performances is desirable for developing advanced devices and equipment. In this study, a novel strategy to prepare anisotropic wood-based scaffolds with a naturally aligned microchannel structure from balsa wood is demonstrated. The wood microchannels were coated with polydopamine-surface-modified small graphene oxide (PGO) nanosheets via assembly. The highly aligned porous microstructures, with thin wood cell walls and large voids along the cellulose microchannels, allow polymers to enter, resulting in the fabrication of the wood-polymer nanocomposite. The tensile stiffness and strength of the resulting nanocomposite reach 8.10 GPa and 90.3 MPa with a toughness of 5.0 MJ m^-3. The thermal conductivity of the nanocomposite is improved significantly by coating a PGO layer onto the wood scaffolds. The nanocomposite exhibits not only ultrahigh thermal conductivity (in-plane about 5.5 W m^-1 K^-1 and through-plane about 2.1 W m^-1 K^-1) but also satisfactory electrical insulation (volume resistivity of about 10¹⁵ Ω·cm). Therefore, the results provide a strategy to fabricate thermal management materials with excellent mechanical properties.

High Thermal Conductivity and Mechanical Strength Phase Change Composite with Double Supporting Skeletons for Industrial Waste Heat Recovery

The "solid-liquid" leakage and low thermal conductivity of organic phase change materials limit their wide range of applications. In this paper, a novel carbon fiber/boron nitride (CF/BN)-based nested structure was constructed, and then, a series of poly(ethylene glycol) (PEG)-based phase change composites (PCCs) with high thermal conductivity and mechanical strength were prepared via the simple vacuum adsorption technology by employing the CF/BN nested structure as the heat conduction path and supporting material and the in situ obtained cross-linking epoxy resin as another supporting material. The thermal conductivity of the obtained PCC is as high as 0.81 W/m K, which is 7.4 times higher than that sample without the CF/BN nested structure. The support of the double skeletons confers the obtained PCCs with excellent mechanical strength. Surprisingly, there is not any deformation for PCCs under the pressure of 128.5 times its own weight during the phase change process. In addition, the phase change enthalpy of the obtained PCC is as high as 107.9 J/g. All the results indicate that the obtained PEG-based PCCs possess huge application potential in the field of industrial waste heat recovery.

Recent Advances in Design and Preparation of Polymer-Based Thermal Management Material

The boosting of consumer electronics and 5G technology cause the continuous increment of the power density of electronic devices and lead to inevitable overheating problems, which reduces the operation efficiency and shortens the service life of electronic devices. Therefore, it is the primary task and a prerequisite to explore innovative material for meeting the requirement of high heat dissipation performance. In comparison with traditional thermal management material (e.g., ceramics and metals), the polymer-based thermal management material exhibit excellent mechanical, electrical insulation, chemical resistance and processing properties, and therefore is considered to be the most promising candidate to solve the heat dissipation problem. In this review, we summarized the recent advances of two typical polymer-based thermal management material including thermal-conduction thermal management material and thermal-storage thermal management material. Furtherly, the structural design, processing strategies and typical applications for two polymer-based thermal management materials were discussed. Finally, we proposed the challenges and prospects of the polymer-based thermal management material. This work presents new perspectives to develop advanced processing approaches and construction high-performance polymer-based thermal management material.

Advances in Liquid Crystalline Epoxy Resins for High Thermal Conductivity

Epoxy resin (EP) is one of the most famous thermoset materials. In general, because EP has a three-dimensional random network, it possesses thermal properties similar to those of a typical heat insulator. Recently, there has been substantial interest in controlling the network structure of EP to create new functionalities. Indeed, the modified EP, represented as liquid crystalline epoxy (LCE), is considered promising for producing novel functionalities, which cannot be obtained from conventional EPs, by replacing the random network structure with an oriented one. In this paper, we review the current progress in the field of LCEs and their application to highly thermally conductive composite materials.

Thermal interface materials with graphene fillers: review of the state of the art and outlook for future applications

We review the current state-of-the-art graphene-enhanced thermal interface materials for the management of heat in the next generation of electronics. Increased integration densities, speed and power of electronic and optoelectronic devices require thermal interface materials with substantially higher thermal conductivity, improved reliability, and lower cost. Graphene has emerged as a promising filler material that can meet the demands of future high-speed and high-powered electronics. This review describes the use of graphene as a filler in curing and non-curing polymer matrices. Special attention is given to strategies for achieving the thermal percolation threshold with its corresponding characteristic increase in the overall thermal conductivity. Many applications require high thermal conductivity of composites, while simultaneously preserving electrical insulation. A hybrid filler approach, using graphene and boron nitride, is presented as a possible technology providing for the independent control of electrical and thermal conduction. The reliability and lifespan performance of thermal interface materials is an important consideration towards the determination of appropriate practical applications. The present review addresses these issues in detail, demonstrating the promise of graphene-enhanced thermal interface materials compared to alternative technologies.

Artificial Nacre Epoxy Nanomaterials Based on Janus Graphene Oxide for Thermal Management Applications

Owing to the development of microelectronics, demands for excellent thermal dissipation materials have substantially increased. Learning from natural nacre, thermally conductive epoxy nanocomposites were prepared based on asymmetrically polydopamine-functionalized Janus graphene oxide (JPGO) scaffolds. The required highly oriented JPGO scaffolds were prepared via the bidirectional freeze-casting method. With the addition of epoxy resin, the resulting nanocomposite reveals anisotropic thermal properties. With the total content of the JPGO scaffold being 0.93 wt %, almost 35 times enhancement of in-plane thermal conductivity (perpendicular to the lamellar structure) (∼5.6 W m^-1 K^-1) has been obtained. The single-side-functionalized JPGO scaffolds play an important role in forming thermal conductive networks for the epoxy nanocomposites. Importantly, the nanocomposites present electrically insulating properties (>10¹⁴ Ω cm). Such high-performance nanocomposites have promising applications for thermal management in electronic devices.