Free-standing nanopapers
based on graphene and its related materials
have been widely studied and proposed for flexible heat spreader applications.
Given that these materials are typically brittle, this work reports
the exploitation of polycaprolactone (PCL) as a polymer binder to
enhance resistance and flexibility of nanopapers based on graphite
nanoplates (GNP), while maintaining a high thermal conductivity. Properties
of nanopapers appear to correlate with the excellent PCL adhesion
and strong nucleation of the surface of GNP flakes. Furthermore, different
crystalline populations were observed for PCL within the nanopaper
and were investigated in detail via differential scanning calorimetry
advanced techniques and X-ray diffraction. These demonstrated the
coexistence of conventional unoriented PCL crystals, oriented PCL
crystals obtained as a consequence of the strong nucleation effect,
and highly stable PCL fractions explained by the formation of crystalline
pre-freezing layers, the latter having melting temperatures well above
the equilibrium melting temperature for pristine PCL. This peculiar
crystallization behavior of PCL, reported in this paper for the first
time for a tridimensional structure, has a direct impact on material
properties. Indeed, the presence of high thermal stability crystals,
strongly bound to GNP flakes, coexisting with the highly flexible
amorphous fraction, delivers an ideal solution for the strengthening
and toughening of GNP nanopapers. Thermomechanical properties of PCL/GNP
nanopapers, investigated both on a heating ramp and by creep tests
at high temperatures, demonstrated superior stiffness well above the
conventional melting temperature of PCL. At the same time, a thermal
conductivity > 150 W/m·K was obtained for PCL/GNP nanopapers,
representing a viable alternative to traditional metals in terms of
heat dissipation, while affording flexibility and light weight, unmatched
by conventional thermally conductive metals or ceramics. Besides the
obtained performance, the formation of polymer crystals that are stable
above the equilibrium melting temperature constitutes a novel approach
in the self-assembly of highly ordered nanostructures based on graphene
and related materials.