Effect of Alignment on Enhancement of Thermal Conductivity of Polyethylene-Graphene Nanocomposites and Comparison with Effective Medium Theory

Thermal Conductive Polymer Composites: Recent Progress and Applications

As microelectronics technology advances towards miniaturization and higher integration, the imperative for developing high-performance thermal management materials has escalated. Thermal conductive polymer composites (TCPCs), which leverage the benefits of polymer matrices and the unique effects of nano-enhancers, are gaining focus as solutions to overheating due to their low density, ease of processing, and cost-effectiveness. However, these materials often face challenges such as thermal conductivities that are lower than expected, limiting their application in high-performance electronic devices. Despite these issues, TCPCs continue to demonstrate broad potential across various industrial sectors. This review comprehensively presents the progress in this field, detailing the mechanisms of thermal conductivity (TC) in these composites and discussing factors that influence thermal performance, such as the intrinsic properties of polymers, interfacial thermal resistance, and the thermal properties of fillers. Additionally, it categorizes and summarizes methods to enhance the TC of polymer composites. The review also highlights the applications of these materials in emerging areas such as flexible electronic devices, personal thermal management, and aerospace. Ultimately, by analyzing current challenges and opportunities, this review provides clear directions for future research and development.

Superior enhancement in thermal conductivity of epoxy/graphene nanocomposites through use of dimethylformamide (DMF) relative to acetone as solvent

This method article describes the fabrication of graphene-epoxy nanocomposites using two different solvents, dimethylformamide (DMF) and acetone, and validates the resulting thermal conductivity improvements. The study compared the two solvents at a filler composition of 7 wt% and found that DMF resulted in more uniform dispersion of graphene nanoparticles in the epoxy matrix, leading to a 44% improvement in thermal conductivity compared to acetone. Laser scanning confocal microscopy (LSCM) imaging showed that DMF-based composites had more evenly dispersed graphene nanoplatelets than acetone-based composites, which exhibited larger graphene agglomerations. Effective medium theory calculations showed that DMF led to almost 35% lower interface thermal resistance between graphene and epoxy compared to acetone. The validated fabrication method and findings provide new possibilities for developing high thermal conductivity graphene-epoxy nanocomposites for various thermal management applications.•This article describes methods for fabricating graphene-epoxy composites using acetone and DMF as solvents, and validates that DMF is better for achieving higher thermal conductivity in the composite.

Polymeric Materials Selection for Flexible Pulsating Heat Pipe Manufacturing Using a Comparative Hybrid MCDM Approach

The right choice of polymeric materials plays a vital role in the successful design and manufacture of flexible fluidic systems, as well as heat transfer devices such as pulsating heat pipes. The decision to choose an acceptable polymeric material entails a variety of evaluation criteria because there are numerous competing materials available today, each with its own properties, applications, benefits, and drawbacks. In this study, a comparative hybrid multi-criteria decision-making (MCDM) model is proposed for evaluating suitable polymeric materials for the fabrication of flexible pulsating heat pipes. The decision model consists of fourteen evaluation criteria and twelve alternative materials. For this purpose, three different hybrid MCDM methods were applied to solve the material selection problems (i.e., AHP-GRA, AHP-CoCoSo, and AHP-VIKOR). According to the results obtained, PTFE, PE, and PP showed promising properties. In addition, Spearman's rank correlation analysis was performed, and the hybrid methods used produced consistent rankings with each other. By applying MCDM methods, it was concluded that PTFE is the most suitable material to be preferred for manufacturing flexible pulsating heat pipes. In addition to this result, PE and PP are among the best alternatives that can be recommended after PTFE. The study supports the use of MCDM techniques to rank material choices and enhance the selection procedure. The research will greatly assist industrial managers and academics involved in the selection process of polymeric materials.

Polymer and Composite Materials in Two-Phase Passive Thermal Management Systems: A Review

The application of polymeric and composite materials in two-phase passive heat transfer devices is reviewed critically, with a focus on advantages and disadvantages of these materials in thermal management systems. Recent technology developments led to an increase of the power density in several applications including portable electronics, space and deployable systems, etc., which require high-performance and compact thermal management systems. In this context, passive two-phase systems are the most promising heat transfer devices to dissipate large heat fluxes without external power supply. Usually, heat transfer systems are built with metals due to their excellent thermal properties. However, there is an increasing interest in replacing metallic materials with polymers and composites that can offer cost-effectiveness, light weight and high mechanical flexibility. The present work reviews state-of the-art applications of polymers and composites in two-phase passive thermal management systems, with an analysis of their limitations and technical challenges.

Remarkable Thermal Performance Enhancement of Micro Heat Pipes with Graphene-Nanoplatelet Nano-Wicks

The ultrafast water permeation property of graphene nanoplatelets (GNPs) synergically enhances the evaporation and water circulation processes in a micro heat pipe (MHP). An MHP is a promising phase-change heat-transfer device capable of transferring large amounts of heat energy efficiently. The hydrophobic, atomically smooth carbon walls of GNPs nanostructures provide a network of nanocapillaries that allows water molecules to intercalate frictionlessly among the graphene layers. Together with the attraction force of the oxygenated functional groups, a series of hydrophobic and hydrophilic surfaces are formed that significantly improve the water circulation rate. The intercalation of water molecules encourages the formation of water-thin film for film-wise evaporation. The effect of nano-wick thickness on the thermal performance of the MHP is investigated. A thinner GNP nano-wick is more favorable to film-wise evaporation while a thicker nano-wick promotes a higher water circulation rate from the condenser to the evaporator, leading to the existence of an optimal thickness. By benchmarking with the uncoated MHP, the thermal conductance of an MHP with a 46.9-µm GNP nano-wick manifests a maximum enhancement of 128%. This study provides insights on the feasible implementation of GNP nano-wicks into a highly efficient micro-scale electronics cooling device for environmental sustainability.

Enhanced Electromagnetic Shielding and Thermal Conductive Properties of Polyolefin Composites with a Ti3C2Tx MXene/Graphene Framework Connected by a Hydrogen-Bonded Interface

The rapid increase of operation speed, transmission efficiency, and power density of miniaturized devices leads to a rising demand for electromagnetic interference (EMI) shielding and thermal management materials in the semiconductor industry. Therefore, it is essential to improve both the EMI shielding and thermal conductive properties of commonly used polyolefin components (such as polyethylene (PE)) in electronic systems. Currently, melt compounding is the most common method to fabricate polyolefin composites, but the difficulty of filler dispersion and high resistance at the filler/filler or filler/matrix interface limits their properties. Here, a fold fabrication strategy was proposed to prepare PE composites by incorporation of a well-aligned, seamless graphene framework premodified with MXene nanosheets into the matrix. We demonstrate that the physical properties of the composites can be further improved at the same filler loading by nanoscale interface engineering: the formation of hydrogen bonds at the graphene/MXene interface and the development of a seamlessly interconnected graphene framework. The obtained PE composites exhibit an EMI shielding property of ∼61.0 dB and a thermal conductivity of 9.26 W m^-1 K^-1 at a low filler content (∼3 wt %, including ∼0.4 wt % MXene). Moreover, other thermoplastic composites with the same results can also be produced based on our method. Our study provides an idea toward rational design of the filler interface to prepare high-performance polymer composites for use in microelectronics and microsystems.

The superior effect of edge functionalization relative to basal plane functionalization of graphene in enhancing the thermal conductivity of polymer-graphene nanocomposites - a combined molecular dynamics and Green's functions study

To achieve polymer-graphene nanocomposites with high thermal conductivity (k), it is critically important to achieve efficient thermal coupling between graphene and the surrounding polymer matrix through effective functionalization schemes. In this work, we demonstrate that edge-functionalization of graphene nanoplatelets (GnPs) can enable a larger enhancement of effective thermal conductivity in polymer-graphene nanocomposites relative to basal plane functionalization. Effective thermal conductivity for the edge case is predicted, through molecular dynamics simulations, to be up to 48% higher relative to basal plane bonding for 35 wt% graphene loading with 10 layer thick nanoplatelets. The beneficial effect of edge bonding is related to the anisotropy of thermal transport in graphene, involving very high in-plane thermal conductivity (∼2000 W m^-1 K^-1) compared to the low out-of-plane thermal conductivity (∼10 W m^-1 K^-1). Likewise, in multilayer graphene nanoplatelets (GnPs), the thermal conductivity across the layers is even lower due to the weak van der Waals bonding between each pair of layers. Edge functionalization couples the polymer chains to the high in-plane thermal conduction pathway of graphene, thus leading to overall high thermal conductivity of the composite. Basal-plane functionalization, however, lowers the thermal resistance between the polymer and the surface graphene sheets of the nanoplatelet only, causing the heat conduction through inner layers to be less efficient, thus resulting in the basal plane scheme to be outperformed by the edge scheme. The present study enables fundamentally novel pathways for achieving high thermal conductivity polymer nanocomposites.

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.

Chemically Edge-Carboxylated Graphene Enhances the Thermal Conductivity of Polyetherimide-Graphene Nanocomposites

In this work, we demonstrate that edge oxidation of graphene can enable larger enhancement in thermal conductivity (k) of graphene nanoplatelet (GnP)/polyetherimide (PEI) composites relative to oxidation of the basal plane of graphene. Edge oxidation offers the advantage of leaving the basal plane of graphene intact, preserving its high in-plane thermal conductivity (k_in > 2000 W m^-1 K^-1), while, simultaneously, the oxygen groups introduced on the graphene edge enhance interfacial thermal conductance through hydrogen bonding with oxygen groups of PEI, enhancing the overall polymer composite thermal conductivity. Edge oxidation is achieved in this work by oxidizing graphene in the presence of sodium chlorate and hydrogen peroxide, thereby introducing an excess of carboxyl groups on the edge of graphene. Basal plane oxidation of graphene, on the other hand, is achieved through the Hummers method, which distorts the sp² carbon-carbon network of graphene, dramatically lowering its intrinsic thermal conductivity, causing the BGO/PEI (BGO = basal-plane oxidized graphene or basal-plane-functionalized graphene oxide) composite's k value to be even lower than pristine GnP/PEI composite's k value. The resulting thermal conductivity of the EGO/PEI (EGO = edge-oxidized graphene or edge-functionalized graphene oxide) composite is found to be enhanced by 18%, whereas that of the BGO/PEI composite is diminished by 57%, with respect to the pristine GnP/PEI composite with 10 wt % GnP content. Two-dimensional Raman mapping of GnPs is used to confirm and distinguish the location of oxygen functional groups on graphene. The superior effect of edge bonding presented in this work can lead to fundamentally novel pathways for achieving high thermal conductivity polymer composites.

Relationship between the Microstructure and Performance of Graphene/Polyethylene Composites Investigated by Positron Annihilation Lifetime Spectroscopy

The quantitative characterization of microstructure is most desirable for the establishment of structure-property relationships in polymer nanocomposites. In this work, the effects of graphene on the microstructure, mechanical, electrical, and thermal properties of the obtained graphene/polyethylene (PE) composites were investigated. In order to reveal the structure-performance relationship of graphene/PE composites, especially for the effects of the relative free volume fraction (fr) and interfacial interaction intensity (β), positron annihilation lifetime spectroscopy (PALS) was employed for its quantitative description. The relative free volume fraction fr gives a good explanation of the variation for surface resistivity, melting temperature, and thermal stability, and the variation of tensile strength and thermal conductivity agree well with the results of interfacial interaction intensity β. The results showed that fr and β have a significant effect on the properties of the obtained graphene/PE composites, and the effect on the properties was revealed.

Recent Advances in Polymer Nanocomposites Based on Polyethylene and Polyvinylchloride for Power Cables

Polymer nanocomposites used in underground cables have been of great interest to researchers over the past 10 years. Their preparation and the dispersion of the nanoparticles through the polymer host matrix are the key factors leading to their enhanced dielectric properties. Their important dielectric properties are breakdown strength, permittivity, conductivity, dielectric loss, space charge accumulation, tracking, and erosion, and partial discharge. An overview of recent advances in polymer nanocomposites based on LDPE, HDPE, XLPE, and PVC is presented, focusing on their preparation and electrical properties.