Enhanced thermal properties of HDPE/EG nanocomposites via synergy of multi‐source pulsating flow and phase transition

Abstract A new melt mixing and in‐situ exfoliation method based on the synergy of multi‐source pulsating flow and phase transition (MSPFPT) was reported. The corresponding device was also developed, and the structure and mixing process of the mixer were introduced in detail. High‐density polyethylene (HDPE)/expanded graphite (EG) composites were prepared via this new mixer, and microstructure and thermal properties of the composites were comprehensively investigated. Morphological analyses demonstrate that MSPFPT method promotes the efficient exfoliation and uniform dispersion of EG. The well‐exfoliated EG layers form more thermal conductive paths in the composites prepared by MSPFPT, increasing thermal conductivity from 0.47 of pure HDPE to 1.16 W/(m·K) with 9 wt.% EG. The crystallinity degree of HDPE is increased by 11.1%. The increment of crystallinity reduces phonon scattering, which further confirms that MSPFPT method can significantly improve the thermal performance. The research provides a practical strategy for fabricating high‐performance composites filled with layered fillers.