Largely enhanced thermal and electrical conductivity via constructing double percolated filler network in polypropylene/expanded graphite – Multi-wall carbon nanotubes ternary composites

In this study, we report a sharp increase of both thermal and electrical conductivity in polypropylene (PP) via formation of double percolated filler network with dense small-sized multi-wall carbon nanotubes (MWCNT) network located within loosened large-sized expanded graphite (EG) network. The electrical conductivity of PP/EG composites which levels off after the percolation threshold can be further enhanced by adding MWCNT and is increased two orders of magnitude as the content of MWCNT reaches to its threshold. Besides, the thermal conductivity of PP/EG-MWCNT increases by 38.5% compared to PP/EG and is much higher than PP/MWCNT. Furthermore, an excellent electromagnetic interference shielding effectiveness of ∼60 dB is obtained at the sample thickness of only 1.3 mm. Then, effective medium theory model is applied to analyze the mechanism for the largely enhanced thermal and electrical conductivity. It is suggested that formation of double percolated filler network, in which three types of connections exist between EG and EG, EG and MWCNT as well as MWCNT and MWCNT, could effectively reduce the interface thermal resistance. Our work is important and provides some new idea for the preparation of polymer composites with excellent thermal and electrical conductivity via constructing double percolated filler network.