Multiple shearing-induced high alignment in polyethylene/graphene films for enhancing thermal conductivity and solar-thermal conversion performance

The simultaneous achievement of ordered alignment for fillers and polymer matrix is highly desired in polymer-based thermally conductive composites, but it is still extremely challenging. Herein, we put forward a layer-by-layer scraping (LbLS) method to simultaneously arrange ultra-high molecular weight polyethylene (UHPE) chains and graphene nanoplates (GNP) into a highly oriented structure. When UHPE/GNP gel suffering the strong shearing effect during LbLS process, the inner UHPE chains and GNP were dragged and orderly arranged along shearing direction, and these oriented structures were retained after rapidly drying by distillation. After layer-by-layer stacking, nacre-like UHPE/GNP films with tightly layered structure were obtained. By adjusting the scraping gap from 200 to 50 μm, the oriented structure can be effectively reinforced with the Herman orientation factors f increasing from 0.83 to 0.88 for GNP and 0.75 to 0.82 for UHPE chains. The highly ordered structure can form a tight and oriented thermal conduction network with low interfacial thermal resistance in plane. The LbLS composite film thus significantly enhanced the in-plane thermal conductivity up to 28.88 W/mK, compared with traditional solution casting film (9.63 W/mK). Moreover, the highly oriented structure can significantly increase the solar-thermal conversion performance (58.1 °C@100 mW/cm2) by improving its light absorption ability comparing to that of solution casting film. Besides, the mechanical strength and toughness that depend on the filler and chain alignment were effectively increased by the oriented structure.