High-speed melt stretching produces polyethylene nanocomposite film with ultrahigh mechanical strength

Compared to polymer fibers, it is still challenging for fabricating large-scale polymer products with superb mechanical properties. Herein, high density polyethylene (HDPE) films reinforced with carbon nanotubes (CNTs) were prepared via an ingenious high-speed melt stretching strategy. With employing a homemade two-drum extensional rheometer, the maximum 80 × stretch ratio of supercooled melt was realized within very short time of 220 ms. The achieved nanocomposite films present the highest tensile strength of 147 MPa in reported HDPE-based composites, while the Young's modulus keeps simultaneously a high level of 2300 MPa in spite of low filler fraction of 3 wt%. Furthermore, the nanocomposite films display an excellent erosion resistance, ensuring the durability in harsh using environments. Microstructural characterization indicates a strong synergy between high-speed melt stretching and CNTs in (1) forming the densely distributed shish-kebab superstructures, (2) making a nearly perfect orientation of shish-kebab crystal and (3) reinforcing the physical connectivity of shish-kebab network. The construction of such characteristic microstructures greatly improves the transfer of mechanical load and underlies a significant enhancement on the mechanical performance. Due to the ultrastrong nanocomposite films fabricated directly by melt processing, the current work is of guiding significance in engineering practice and lights a feasible path towards expanding applications of general plastics to some special occasions like collision protection and structural materials. • PE/C nanocomposite films are fabricated by high-speed melt stretching. • Films show ultrahigh mechanical properties and excellent erosion resistance. • Dense shish-kebab superstructures with nearly perfect orientation are formed. • CNTs greatly reinforce physical connectivity of shish-kebab crystal network.