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Polypropylene (PP)/exfoliated graphite nanoplatelet (xGnP) nanocomposites with various intrinsic aspect ratios of graphite nanoplatelets (GnPs; large and small in diameter) were prepared by a melt-mixing procedure. Transmission electron microscopy showed that all types of xGnP were well-dispersed in the polymer matrix. The effects of the dimensions and loading of the xGnPs on the morphology, mechanical reinforcement, and electrical properties of PP/xGnP were studied. A differential scanning calorimetry study of the PP/xGnP morphology indicated that all types of xGnP additives were heterogeneous nucleation sites for PP crystallization. Tensile testing, DMA, and thermogravimetric analysis of PP/xGnPs with different types of GnP additives showed enhancements in their mechanical properties, heat resistance, and thermal stability compared to plain PP. We also found a significant increase in the conductivity of PP/xGnP. The PP/xGnP with a large diameter of GnPs demonstrated the lowest percolation threshold, equal to 4 vol % of the xGnP loading. The mechanical properties were estimated by means of micromechanical modeling.

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