An electrospinning process was successfully used to fabricate polyethylene oxide/cellulose nanocrystal (PEO/CNC) composite nanofibrous mats. Transition of homogeneous to heterogeneous microstructures was achieved by tailoring the concentration of PEO/CNC mixture in the solution from 5 to 7 wt %. Morphology investigation of the obtained nanofibers demonstrated that rod-shaped CNCs were well-dispersed in the as-spun nanofibers and highly aligned along the nanofiber long-axis. PEO/CNC nanofibers became more uniform and smaller in diameter with increased CNC-loading level. The heterogeneous composite mats were composed of rigid-flexible bimodal nanofibers. Results of structure characterization indicated that the incorporated CNCs interacted strongly with the PEO matrix through hydrogen bonding. Mechanical properties of both types of mats were effectively improved by using CNCs, with heterogeneous mats being stronger than their homogeneous counterparts for all compositions (0-20 wt % CNC contents). When a smaller diameter needle was used to form homogeneous mats, enhanced thermal and mechanical properties were obtained.

Effective removal of oils from water is of global significance for environmental protection. In this study, we investigate the hydrophobicity and oleophilicity of open-cell polymer foams prepared in a continuous and scalable extrusion process. The material used to prepare the open-cell foams is a fibrillar blend of polypropylene (PP) and polytetrafluoroethylene (PTFE). Scanning electron microscopy (SEM) images of the morphology of the PP/PTFE fibrillar blend reveal that the PTFE has a fibrillar morphology in the PP matrix. SEM micrograph of the extruded foam shows the formation of an interconnected open-cell structure. Using nitrogen pycnometry, the open-cell content is estimated to be 97.7%. A typical bulk density of the open-cell foam is measured to be about 0.07 g cm(-3) corresponding to a void fraction of 92%. Thus, a large three-dimensional space is made available for oil storage. A drop of water on the cross-section of the extruded open-cell foam forms a contact angle of 160° suggesting that the open-cell foam exhibits superhydrophobicity. The open-cell foam can selectively absorb various petroleum products, such as octane, gasoline, diesel, kerosene, light crude oil, and heavy crude oil from water and the uptake capacities range from about 5 to 24 g g(-1). The uptake kinetics can be enhanced by exposing the open-cell foam to high intensity ultrasound which increases the surface porosity of the thin, impervious, foam "skin" layer. The reusability of the foam can be improved by using a matrix polymer which demonstrates superior elastic properties and prevents the foams from undergoing a large permanent deformation upon compression to "squeeze out" the oil. For example, when the PP homopolymer matrix is replaced with a PP random copolymer, the permanent deformation for 10 compressive cycles is reduced from about 30% to 10%. To the best of our knowledge, these PP-based open-cell foams outperform PP-based absorbents conventionally used for oil-spill cleanup applications such as nonwoven PP fibers or melt-blown PP pads.

As electronic devices become increasingly miniaturized, their thermal management becomes critical. Efficient heat dissipation guarantees their optimal performance and service life. Graphene nanoplatelets (GnPs) have excellent thermal properties that show promise for use in fabricating commercial polymer nanocomposites with high thermal conductivity. Herein, an industrially viable technique for manufacturing a new class of lightweight GnP-polymer nanocomposites with high thermal conductivity is presented. Using this method, GnP-high-density polyethylene (HDPE) nanocomposites with a microcellular structure are fabricated by melt mixing, which is followed by supercritical fluid (SCF) treatment and injection molding foaming, which adds an extra layer of design flexibility. Thus, the microstructure is tailored within the nanocomposites and this improves their thermal conductivity. Therefore, the SCF-treated HDPE 17.6 vol % GnP microcellular nanocomposites have a solid-phase thermal conductivity of 4.13 ± 0.12 W m K. This value far exceeds that of their regular injection-molded counterparts (2.09 ± 0.03 W m K) and those reported in the literature. This dramatic improvement results from in situ GnPs' exfoliation and dispersion, and from an elevated level of random orientation and interconnectivity. Thus, this technique provides a novel approach to the development of microscopically tailored structures for the production of lighter and more thermally conductive heat sinks for next generations of miniaturized electronic devices.

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Dielectric polymer nanocomposites with high dielectric constant (ε') and low dielectric loss (tan δ) are extremely desirable in the electronics industry. Percolative polymer-graphene nanoplatelet (GnP) composites have shown great promise as dielectric materials for high-performance capacitors. Herein, an industrially-viable technique for manufacturing a new class of ultralight polymer composite foams using commercial GnPs with excellent dielectric performance is presented. Using this method, the high-density polyethylene (HDPE)-GnPs composites with a microcellular structure were fabricated by melt-mixing. This was followed by supercritical fluid (SCF) treatment and physical foaming in an extrusion process, which added an extra layer of design flexibility. The SCF treatment effectively in situ exfoliated the GnPs in the polymer matrix. Moreover, the generation of a microcellular structure produced numerous parallel-plate nanocapacitors consisting of GnP pairs as electrodes with insulating polymer as nanodielectrics. This significantly increased the real permittivity and decreased the dielectric loss. The ultralight extruded HDPE-1.08 vol % GnP composite foams, with a 0.15 g·cm density, had an excellent combination of dielectric properties (ε' = 77.5, tan δ = 0.003 at 1 × 10 Hz), which were superior to their compression-molded counterparts (ε' = 19.9, tan δ = 0.15 and density of = 1.2 g·cm) and to those reported in the literature. This dramatic improvement resulted from in situ GnP's exfoliation and dispersion, as well as a unique GnP parallel-plate arrangement around the cells. Thus, this facile method provides a scalable method to produce ultralight dielectric polymer nanocomposites, with a microscopically tailored microstructure for use in electronic devices.