Interlayer Polymerization in Chemically Expanded Graphite for Preparation of Highly Conductive, Mechanically Strong Polymer Composites

The large-scale application of graphene–polymer composites needs a simple, low-cost method that simplifies the preparation process of graphene and optimizes the structure and properties of composites. We propose the first interlayer polymerization in chemically expanded graphite (CEG) with large specific surface areas, which allows CEG to be spontaneously exfoliated into single- and few-layer graphene in poly(methyl methacrylate) (PMMA). Our results demonstrate that besides weakened interlayer interactions, the surface wettability of CEG to monomers is a critical prerequisite for the desired graphene exfoliation, dispersion, and performance optimization of composites. The slightly oxidized CEG (LCEG) improved to some extent the affinity for the monomer but is not sufficient to achieve complete exfoliation of LCEG, so that the resulting composites reveal the mechanical and electrical properties that are far poorer than those of the surface-modified LCEG-based composites. The latter not only exhibit a significantly enhanced elastic modulus, increased as much as 3-fold relative to that of the neat PMMA, but also show an extremely high electrical conductivity, of >1700 S/m. Such a novel interlayer polymerization approach is expected to accelerate the use of industrial applications of a wide range of graphene-based composites.