Ultrafast Fabrication of Graphene-Reinforced Nanocomposites via Synergy of Steam Explosion and Alternating Convergent-Divergent Flow.

Producing high-quality graphene and polymer/graphene nanocomposite is facing the problems of complex procedure, low efficiency, and serious resource waste. To explore a new fabrication approach with high efficiency and low cost is crucial for solving these technical issues, which becomes a current research hotspot and also a great challenge. Herein, a one-step melt mixing strategy based on the synergy of steam explosion and alternating convergent-divergent flow, is innovatively developed to fabricate high-density polyethylene (HDPE)/graphene nanocomposites using industrial-grade expanded graphite (EG) without chemical agents and complex procedures. The co-action of the external force derived from elongational melts and the internal force generated by steam explosion make EG ultrafastly exfoliate into few-layer graphene nanosheets (GNS) and simultaneously disperse in melts within 4 min. The as-produced GNS have a lateral size of over 5 µm and a minimum thickness of 1.4 nm, can introduce super heterogeneous nucleation to HDPE macromolecules and greatly increases nanocomposite crystallinity up to 86.5%. Moreover, plentiful HDPE crystallites and well-dispersed GNS jointly form an improved thermally-conductive network, making nanocomposites with a rapid-respond ability in solar-to-thermal conversion and heat dissipation. This facile strategy will facilitate the development of scalable production and wide application of high-performance graphene and highly-filled nanocomposites.