Large-Scale Production of Rectorite Nanosheets and Their Co-Assembly with Aramid Nanofibers for High-Performance Electrical Insulating Nanopapers

Compared with raw rectorite microplatelets (RMs), rectorite nanosheets (RNs) have considerably greater application prospects in the preparation of advanced composite materials because of their larger aspect ratio, higher surface reactivity, and intrinsically superior mechanical and physical properties. However, the difficulty in the efficient preparation of RNs significantly limits their large-scale applications. Here, a scalable poly(vinylpyrrolidone)-assisted stirring approach is developed to prepare ultrathin RNs from the abundant natural RMs. A higher production rate (≈0.675 g h^-1 ) is achieved compared with that of most other nanosheets. Additionally, instead of using conventional time- and energy-consuming high-speed centrifugation, an efficient poly(dienedimethylammonium chloride)-assisted sedimentation strategy is proposed here to rapidly separate the exfoliated RNs from the RN dispersion. Then, the RNs are co-assembled with aramid nanofibers (ANFs) into large-scale nacre-mimetic ANF-RN nanopapers with considerably enhanced mechanical, electrical insulating, and high-temperature-resistant properties compared with pure ANF nanopapers and ANF-RM micropapers. Moreover, these properties are superior to those of previously reported ANF-based nanopapers and commercial insulating micropapers.

Recent Advances in Self-Assembly and Application of Para-Aramids

Poly(p-phenylene terephthalamide) (PPTA) is one kind of lyotropic liquid crystal polymer. Kevlar fibers performed from PPTA are widely used in many fields due to their superior mechanical properties resulting from their highly oriented macromolecular structure. However, the “infusible and insoluble” characteristic of PPTA gives rise to its poor processability, which limits its scope of application. The strong interactions and orientation characteristic of aromatic amide segments make PPTA attractive in the field of self-assembly. Chemical derivation has proved an effective way to modify the molecular structure of PPTA to improve its solubility and amphiphilicity, which resulted in different liquid crystal behaviors or supramolecular aggregates, but the modification of PPTA is usually complex and difficult. Alternatively, higher-order all-PPTA structures have also been realized through the controllable hierarchical self-assembly of PPTA from the polymerization process to the formation of macroscopic products. This review briefly summarizes the self-assembly methods of PPTA-based materials in recent years, and focuses on the polymerization-induced PPTA nanofibers which can be further fabricated into different macroscopic architectures when other self-assembly methods are combined. This monomer-started hierarchical self-assembly strategy evokes the feasible processing of PPTA, and enriches the diversity of product, which is expected to be expanded to other liquid crystal polymers.

Activated Carbon Derived from Carbonization of Kevlar Waste Materials: A Novel Single Stage Method

The augmented demands of textile materials over time have brought challenges in the disposal of substantial volumes of waste generated during the processing and end of life of such materials. Taking into consideration environmental safety due to discarding of textile waste, it becomes critical to recuperate useful products from such waste for economic reasons. The present work deals with the preparation of porous and electrically conductive activated carbon fabric by a novel single stage method of simultaneous carbonization and physical activation of Kevlar feedstock material procured from local industries, for effective electromagnetic (EM) shielding applications. The Kevlar fabric waste was directly carbonized under a layer of charcoal without any intermediate stabilization step at 800 °C, 1000 °C, and 1200 °C, with a heating rate of 300 °C/h and without any holding time. The physical and morphological properties of the activated carbon, influenced by carbonization process parameters, were characterized from EDX, X-ray diffraction, SEM analysis, and BET analysis. Furthermore, the electrical conductivity was analyzed. Finally, the potential application of the activated material for EM shielding effectiveness was analyzed at low (below 1.5 GHz) and high (2.45 GHz) frequencies. The phenomena of multiple internal reflections and absorption of electromagnetic radiations was found dominant in the case of activated carbon fabric produced at higher carbonization temperatures.

Dissolving and Regeneration of meta-Aramid Paper: Converting Loose Structure into Consolidated Networks with Enhanced Mechanical and Insulation Properties

Aramid paper has been widely used in high-voltage motors and transformers due to its excellent insulation property and thermal durability. However, the smoothness and chemical inertness of aramid fibers lead to a loose structure (voids) of aramid paper, which limits its potential applications in harsh environments, such as high-frequency and high-voltage circuits. This work reports a simple and efficient method to improve the mechanical and insulation properties of meta-aramid paper via controllable dissolving and regeneration of aramid fibers. To obtain a dense and robust structure, the pristine meta-aramid paper was immersed in a dimethyl sulfoxide/potassium hydroxide (DMSO/KOH) mixture to make aramid fibers swelled and dissolved, followed by regeneration in water vapor, eventually generating densified aramid paper with fewer voids and enhanced insulation and mechanical performance. Optimum conditions resulted in aramid paper with the best comprehensive performance, and the tensile strength, Young's modulus, and electrical breakdown strength of the consolidated aramid paper were 22.85 MPa, 0.72 GPa, and 15.3 kV/mm, respectively, which were significantly higher than those of the pristine aramid paper (12.53 MPa, 0.41 GPa, and 8.36 kV/mm). Meanwhile, such treatment did not cause any chemical structure change, and thus it still retained the excellent thermal resistance (T_d > 430 °C) of aramid fibers. This simple method can effectively regulate the surface porosity and the mechanical and breakdown strength of aramid paper, as well as provide a generic method for postprocessing and enhancing aramid paper.

Toward high-performance nanofibrillated cellulose/aramid fibrid paper-based composites via polyethyleneimine-assisted decoration of silica nanoparticle onto aramid fibrid

Flexible paper-based nanocomposites dielectrics are of crucial importance in electrical insulation and advanced electrical power systems. In this work, a novel nanofibrillated cellulose/aramid fibrid (NFC/AF) composite was fabricated by vacuum-assisted filtration process. In order to improve the dielectric property of the composites, carboxylated nano-SiO₂ was chemically coated onto aramid fibrid via molecular self-assembly with the aid of phosphoric acid (PA) pretreatment and subsequent polyethyleneimine (PEI) functionalization. It was found that composites prepared by NFC and (PEI/SiO₂)-modified AF (after crosslinking) ((PEI/SiO₂)-AF) showed dense structure, which was mainly due to enhanced interfacial interaction between AF and NFC. Consequently, NFC/(PEI/SiO₂)-AF paper-based composites showed better tensile toughness (∼6 % elongation at break) and mechanical strength (∼36.28 MPa), in comparison with NFC/AF. More importantly, the electrical insulation performance and thermal stability of the composites were significantly improved. Accordingly, this work provides a facile approach to fabricate high-performance dielectric composites especially for high-temperature electrical insulation applications.

Sol–gel synthesis of nanosilica-coated para-aramid fibers and their application in the preparation of paper-based friction materials

A facile method of surface modification to fabricate nanosilica-coated aramid fibers via sol–gel process and their application for paper-based friction materials by wet-forming process.