Breaking Through Bottlenecks for Thermally Conductive Polymer Composites:A Perspective for Intrinsic Thermal Conductivity,Interfacial Thermal Resistance and Theoretics

Rapid development of energy,electrical and electronic technologies has put forward higher requirements for the thermal conductivities of polymers and their composites.However,the thermal conductivity coefficient(λ)values of prepared thermally conductive polymer composites are still difficult to achieve expectations,which has become the bottleneck in the fields of thermally conductive polymer composites.Aimed at that,based on the accumulation of the previous research works by related researchers and our research group,this paper proposes three possible directions for breaking through the bottlenecks:(1)preparing and synthesizing intrinsically thermally conductive polymers,(2)reducing the interfacial thermal resistance in thermally conductive polymer composites,and(3)establishing suitable thermal conduction models and studying inner thermal conduction mechanism to guide experimental optimization.Also,the future development trends of the three above-mentioned directions are foreseen,hoping to provide certain basis and guidance for the preparation,researches and development of thermally conductive polymers and their composites.

“Toolbox”for the Processing of Functional Polymer Composites

Functional polymer composites(FPCs)have attracted increasing attention in recent decades due to their great potential in delivering a wide range of functionalities.These functionalities are largely determined by functional fillers and their network morphology in polymer matrix.In recent years,a large number of studies on morphology control and interfacial modification have been reported,where numerous preparation methods and exciting performance of FPCs have been reported.Despite the fact that these FPCs have many similarities because they are all consisting of functional inorganic fillers and polymer matrices,review on the overall progress of FPCs is still missing,and especially the overall processing strategy for these composites is urgently needed.Herein,a"Toolbox"for the processing of FPCs is proposed to summarize and analyze the overall processing strategies and corresponding morphology evolution for FPCs.From this perspective,the morphological control methods already utilized for various FPCs are systematically reviewed,so that guidelines or even predictions on the processing strategies of various FPCs as well as multi-functional polymer composites could be given.This review should be able to provide interesting insights for the field of FPCs and boost future intelligent design of various FPCs.

The Development of Thermal Conductive Polymer Composites for Heat Sink

The thermal and mechanical properties of the polyamide 6/boron nitride and polyphenylene sulfide/graphite composites have been investigated as a function of composition and size of fillers. The addition of highly thermal conductive h-BN and graphite gives rise to large increase （about 2 times） of thermal conductivity of individual polymer. In PPS/graphite system, the higher conductivity value was obtained when smaller graphites were added. Meanwhile, the tensile and flexural strength are reduced upon increasing filler loading.

Wearable and stretchable conductive polymer composites for strain sensors:How to design a superior one?

Wearable and stretchable strain sensors have potential values in the fields of human motion and health monitoring,flexible electronics,and soft robotic skin.The wearable and stretchable strain sensors can be directly attached to human skin,providing visualized detection for human motions and personal healthcare.Conductive polymer composites(CPC)composed of conductive fillers and flexible polymers have the advantages of high stretchability,good flexibility,superior durability,which can be used to prepare flexible strain sensors with large working strain and outstanding sensitivity.This review has put forward a comprehensive summary on the fabrication methods,advanced mechanisms and strain sensing abilities of CPC strain sensors reported in recent years,especially the sensors with superior performance.Finally,the structural design,bionic function,integration technology and further application of CPC strain sensors are prospected.

The Packaging Materials with Carbon Nanotube/Polymer Composites

A polymer-based carbon nano-tubes (CNTs) composite with high electromagnetic (EM) wave shielding effectiveness (SE) and with high mechanical property is developed for packaging of electronic modulus or devices.The liquid crystal polymers (LCP) and melamine formaldehydes (MF) polymer are used to study the orientation effect of CNTs in various polymeric matrix.The influences of orientation,aspect ratio,and mass fraction of CNTs upon the shielding effectiveness (SE) of CNTs-composites are investigated.The higher the orientation,aspect ratio,and weight percentages of nano-materials are, the higher the SE of the carbon composites.The highest SE for the CNTs/LCP nano composite obtained is more than 62 dB. This results may lead to the developing for CPU IC chip packaging.

Material Selection of a Natural Fibre Reinforced Polymer Composites using an Analytical Approach

Material selection has become a critical part of design for engineers,due to availability of diverse choice of materials that have similar properties and meet the product design specification.Implementation of statistical analysis alone makes it difficult to identify the ideal composition of the final composite.An integrated approach between statistical model and micromechanical model is desired.In this paper,resultant natural fibre and polymer matrix from previous study is used to estimate the mechanical properties such as density,Young’s modulus and tensile strength.Four levels of fibre loading are used to compare the optimum natural fibre reinforced polymer composite(NFRPC).The result from this analytical approach revealed that kenaf/polystyrene(PS)with 40%fibre loading is the ideal composite in automotive component application.It was found that the ideal composite score is 1.156 g/cm^(3),24.2 GPa and 413.4 MPa for density,Young’s modulus and tensile strength,respectively.A suggestion to increase the properties on Young’s modulus are also presented.This work proves that the statistical model is well incorporated with the analytical approach to choose the correct composite to use in automotive application.

Thermal conductivity model of filled polymer composites

Theoretical and empirical models for predicting the thermal conductivity of polymer composites were summarized since the 1920s.The effects of particle shape,filler amount,dispersion state of fillers,and interfacial thermal barrier on the thermal conductivity of filled polymer composites were investigated,and the agreement of experimental data with theoretical models in literatures was discussed.Silica with high thermal conductivity was chosen to mix with polyvinyl-acetate （EVA） copolymer to prepare SiO2/EVA co-films.Experimental data of the co-films＇ thermal conductivity were compared with some classical theoretical and empirical models.The results show that Agari＇s model,the mixed model,and the percolation model can predict well the thermal conductivity of SiO2/EVA co-films.

Effective viscoelastic behavior of particulate polymer composites at finite concentration

Polymeric materials usually present some viscoelastic behavior. To improve the mechanical behavior of these materials, ceramics materials are often filled into the polymeric materials in form of fiber or particle. A micromechanical model was proposed to estimate the overall viscoelastic behavior for particulate polymer composites, especially for high volume concentration of filled particles. The method is based on Laplace transform technique and an elastic model including two-particle interaction. The effective creep compliance and the stress and strain relation at a constant loading rate are analyzed. The results show that the proposed method predicts a significant stiffer response than those based on Mori-Tanaka＇s method at high volume concentration of particles.

Wear and transfer characteristics of carbon fiber reinforced polymer composites under water lubrication

The tribological characteristics of carbon fiber reinforced polymer composites under distilled-water-lubricated-sliding and dry-sliding against stainless steel were comparatively investigated. Scanning electron microscopy (SEM) was utilized to examine composite microstructures and modes of failure. The typical chemical states of elements of the transfer film on the stainless steel were examined with X-ray photoelectron spectroscopy (XPS). Wear testing and SEM analysis show that all the composites hold the lowered friction coefficient and show much better wear resistance under water lubricated sliding against stainless steel than those under dry sliding. The wear of composites is characterized by plastic deformation, scuffing, micro cracking, and spalling under both dry-sliding and water lubricated conditions. Plastic deformation, scuffing, micro cracking, and spalling, however, are significantly abated under water-lubricated condition. XPS analysis conforms that none of the materials produces transfer films on the stainless steel counterface with the type familiar from dry sliding, and the transfer of composites onto the counterpart ring surface is significantly hindered while the oxidation of the stainless steel is speeded under water lubrication. The composites hinder transfer onto the steel surface and the boundary lubricating action of water accounts for the much smaller wear rate under water lubrication compared with that under dry sliding. The easier transfer of the composite onto the counterpart steel surface accounts for the larger wear rate of the polymer composite under dry sliding.

Analysis on the Durability of Hybrid Polymer Composites for Power FGD System

The corrosion condition of flue gas desulfurization (FGD) equipment for the coal-fired power plant was defined as the strong corrosion grade. The lining system of hybrid polymer composite was used in internal cylinder of steel chimney, and a corrosion-resistant and heat-resistant protective layer was formed on the metal surface. The corrosion-resistant and ageing-resistant properties of hybrid polymer composite prepared at low temperature after four years of practical use were investigated by differential scanning calorimeter (DSC), scanning electron microscopy (SEM) and measurement of gravimetric variation, contact angle, abrasion resistance, bonding strength and tensile strength. The properties of hybrid polymer composites prepared at 25℃ and –15℃ were comparatively analyzed in the paper.

Nonlinear Micromechanical Modelling of Transverse Tensile Damage Behavior in Fiber-Reinforced Polymer Composites

The investigation focusing on the mechanical behaviors at the microstructural level in composite materials can provide valuable insight into the failure mechanisms at larger scales.A micromechanics damage model which comprises the coupling of the matrix constitutive model and the cohesive zone(CZM)model at fiber-matrix interfaces is presented to evaluate the transverse tensile damage behaviors of unidirectional(UD)fiber-reinforced polymer(FRP)composites.For the polymeric matrix that exhibits highly non-linear mechanical responses,special focus is paid on the formulation of the constitutive model,which characterizes a mixture of elasticity,plasticity as well as damage.The proposed constitutive model includes the numerical implementation of a fracture plane based ellipse-parabola criterion that is an extension of the classic Mohr-Coulomb criterion,corresponding post-yield flow rule and post-failure degradation rule in the fully implicit integration scheme.The numerical results are in good agreement with experimental measurements.It is found that directly using the matrix properties measured at the ply level to characterize the mechanical responses at the constituent level may bring large discrepancies in homogenized stress-strain responses and dominant failure mechanisms.The distribution of fracture plane angles in matrix is predicted,where it is shown to provide novel insight into the microscopic damage initiation and accumulation under transverse tension.

Fabrication and Characterization of Glass Fiber with SiC Reinforced Polymer Composites

Glass Fiber Reinforced Polymeric (GFRP) Composites are most commonly used as bumpers for vehicles, electrical equipment panels, and medical devices enclosures. These materials are also widely used for structural applications in aerospace, automotive, and in providing alternatives to traditional metallic materials. The paper fabricated epoxy and polyester resin composites by using silicon carbide in various proportions along with GFRP. The hand lay-up technique was used to fabricate the laminates. To determine the properties of fabricated composites, the tensile, impact, and flexural tests were conducted. This method of fabrication was very simple and cost-effective. Their mechanical properties like yield strength, yield strain, Young’s modulus, flexural modulus, and impact energy were investigated. The mechanical properties of the GFRP composites were also compared with the fiber volume fraction. The fiber volume fraction plays a major role in the mechanical properties of GFRP composites. Young’s modulus and tensile strength of fabricated composites were modelled and compared with measured values. The results show that composites with epoxy resin demonstrate higher strength and modulus compared to composites with polyester resin.

Preparation technologies for polymer composites with high-directional thermal conductivity:A review

With the rapid development of science and technology,electronic devices are moving towards miniaturization and integration,which brings high heat dissipation requirements.During the heat dissipation process of a heating element,heat may spread to adjacent components,causing a decrease in the performance of the element.To avoid this situation,the ability to directionally transfer heat energy is urgently needed.Therefore,thermal interface materials(TIMs)with directional high thermal conductivity are more critical in thermal management system of electronic devices.For decades,many efforts have been devoted to the design and fabrication of TIMs with high-directional thermal conductivity.Benefiting from the advantage in feasibility,low-cost and scalability,compositing with thermal conductive fillers has been proved to be promising strategy for fabricating the high-directional thermal conductive TIMs.This review summarizes the present preparation technologies of polymer composites with high-directional thermal conductivity based on structural engineering of thermal conductive fillers,focusing on the manufacturing process,mechanisms,achievements,advantages and disadvantages of different technologies.Finally,we summarize the existing problems and potential challenges in the field of directional high thermal conductivity composites.

Advances in 3D printing for polymer composites:A review

The potential of three-dimensional(3D)printing technology in the fabrication of advanced polymer composites is becoming increasingly evident.This review discusses the latest research developments and applications of 3D printing in polymer composites.First,it focuses on the optimization of 3D printing technology,that is,by upgrading the equipment or components or adjusting the printing parameters,to make them more adaptable to the processing characteristics of polymer composites and to improve the comprehensive performance of the products.Second,it focuses on the 3D printable novel consumables for polymer composites,which mainly include the new printing filaments,printing inks,photosensitive resins,and printing powders,introducing the unique properties of the new consumables and different ways to apply them to 3D printing.Finally,the applications of 3D printing technology in the preparation of functional polymer composites(such as thermal conductivity,electromagnetic interference shielding,biomedicine,self-healing,and environmental responsiveness)are explored,with a focus on the distribution of the functional fillers and the influence of the topological shapes on the properties and functional characteristics of the 3D printed products.The aim of this review is to deepen the understanding of the convergence between 3D printing technology and polymer composites and to anticipate future trends and applications.

Recent Progress in Fabrication and Structural Design of Thermal Conductive Polymer Composites

In recent years, the demand direction for electronic equipment has expanded into embedded and miniaturized devices. The heat radiation problem has become one of the most significant factors for hindering the development of electronic devices. Since heat radiation material is one of the important components in electronic devices, the demand for enhancing thermal conductivity is also increasingly urgent. Research on thermal conductive polymer composites has become a major direction for developing functional composites. This work reviewed the recent progress in the fabrication of thermal conductive polymer composites. Five different structures are presented, including the using of single fillers,hybrid fillers, double threshold percolation structure, segregated structure and other complex multiphase structures. Specifically, the preparation of high-performance thermal conductive polymer composites was introduced through the combination of various thermal conductive fillers.Finally, the development direction of high thermal conductive polymer composites was briefly explored.

A Perspective for Developing Polymer-Based Electromagnetic Interference Shielding Composites

The rapid development of aerospace weapons and equipment,wireless base stations and 5G communication technologies has put forward newer and higher requirements for the comprehensive performances of polymer-based electromagnetic interference(EMI)shielding composites.However,most of currently prepared polymer-based EMI shielding composites are still difficult to combine high performance and multi-functionality.In response to this,based on the research works of relevant researchers as well as our research group,three possible directions to break through the above bottlenecks are proposed,including construction of efficient conductive networks,optimization of multi-interfaces for lightweight and multifunction compatibility design.The future development trends in three directions are prospected,and it is hoped to provide certain theoretical basis and technical guidance for the preparation,research and development of polymer-based EMI shielding composites.

Highly Thermally Conductive Polymer/Graphene Composites with Rapid Room‑Temperature Self‑Healing Capacity

Composites that can rapidly self-healing their structure and function at room temperature have broad application prospects.However,in view of the complexity of composite structure and composition,its self-heal is facing challenges.In this article,supramolecular effect is proposed to repair the multistage structure,mechanical and thermal properties of composite materials.A stiff and tough supramolecular frameworks of 2-[[(butylamino)carbonyl]oxy]ethyl ester(PBA)–polydimethylsiloxane(PDMS)were established using a chain extender with double amide bonds in a side chain to extend prepolymers through copolymerization.Then,by introducing the copolymer into a folded graphene film(FGf),a highly thermally conductive composite of PBA–PDMS/FGf with self-healing capacity was fabricated.The ratio of crosslinking and hydrogen bonding was optimized to ensure that PBA–PDMS could completely self-heal at room temperature in 10 min.Additionally,PBA–PDMS/FGf exhibits a high tensile strength of 2.23±0.15 MPa at break and high thermal conductivity of 13±0.2 W m^(−1)K^(−1);of which the self-healing efficiencies were 100%and 98.65%at room temperature for tensile strength and thermal conductivity,respectively.The excellent self-healing performance comes from the efficient supramolecular interaction between polymer molecules,as well as polymer molecule and graphene.This kind of thermal conductive self-healing composite has important application prospects in the heat dissipation field of next generation electronic devices in the future.

Rational design of graphene/polymer composites with excellent electromagnetic interference shielding effectiveness and high thermal conductivity: a mini review

The integration and miniaturization of chips lead to inevitable overheating and increasing electromagnetic interference (EMI) problems, which threaten the performance, stability, and lifetime of electroniccomponents. Therefore, it is important to improve the heat dissipation and EMI shielding performancein device packaging for the steady operation of electronic products. In recent years, due to its intrinsic superior thermal conductivity, proper electrical conductivity, light-weight, and structural adjustability,graphene has been widely used as high thermal and conductive fillers incorporated in the polymer matrix to improve the thermal conductivity and electrical conductivity of composites. This review concludesthe recent development of graphene/polymer composites by using graphene as fillers to improve thethermal conductivity and EMI shielding effectiveness (EMI SE). The structure of graphene embedded inthe composites varies from zero-dimension (0D), one-dimension (1D) to two-dimensions (2D). Moreover,highly thermally and electrically conductive fillers with different dimensions were also modified on thegraphene to improve the composite performance. Finally, this review also makes prospects for the development trend of graphene/polymer composites with high thermal conductivity and EMI SE in the future.

ELECTRICAL PROPERTIES OF CONDUCTIVE POLYMER COMPOSITES PREPARED BY AN INNOVATIONAL METHOD

An innovational method that poly(styrene-co-maleic anhydride)(SMA),a compatibilizer of immiscible nylon6/polystyrene(PA6/PS) blends,was first reacted with carbon black(CB) and then blended with PA6/PS,has been employed to prepare the PA6/PS/(SMA-CB) composites of which CB localized at the interface.In PA6/PS/CB blends,CB was found to preferentially localize in the PA6 phase.However,in the PA6/PS/(SMA-CB) blends,it was found that CB particles can be induced by SMA to localize at the interface.The electrical porperties of PA6/PS/(SMA-CB) composites were investigated.The results showed that the composites exhibited distinct triple percolation behavior,i.e.the percolation is governed by the percolation of CB in SMA phase,the continuity of SMA-CB at the interface and the continuity of PA6/PS interface.The percolation threshold of PA6/PS/(SMA-CB) was only 0.15 wt%,which is much lower than that of PA6/PS/CB.Moreover,the PTC(positive temperature coefficient) intensity of PA6/PS/(SMA-CB) composites was stronger than that of PA6/PS/CB and the negative temperature coefficient(NTC) effect was eliminated.The electrical properties of PA6/PS/(SMA-CB) were explained in terms of its special interface morphology:SMA and CB localize at interphase to form the conductive pathways.

Flexible conductive polymer composites for smart wearable strain sensors

Wearable strain sensors based on flexible conductive polymer composites(FCPCs)have attracted great attention due to their applications in the fields of human–machine interaction,disease diagnostics,human motion detection,and soft robotic skin.In recent decades,FCPC‐based strain sensors with high stretchability and sensitivity,short response time,and excellent stability have been developed,which are expected to be more versatile and intelligent.Smart strain sensors are required to provide wearable comfort,such as breathability,selfcooling ability,and so forth.To adapt to the harsh environment,wearable strain sensors should also be highly adaptive to protect the skin and the sensor itself.In addition,portable power supply system,multisite sensing capability,and multifunctionality are crucial for the next generation of FCPC‐based strain sensor.