2D Nanoparticle Elastomer Composites With In Situ Shear Exfoliation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing graphene-enhanced elastomeric composites (G-EMCs) are multi-step, expensive, and prone to impurities, leading to inhomogeneous mixtures and agglomeration, hindering their commercialization.
Innovation Solution
A cost-effective, one-step process involving the direct exfoliation of layered materials like graphite, hexagonal boron nitride, or molybdenum disulfide into 2D nanoparticles within elastomer precursors using high shear, followed by curing to form uniform nanocomposites with improved mechanical, electrical, and thermal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-step methods are used to produce graphene-enhanced elastomeric composites, then the composites can achieve conductive properties, but the production process becomes expensive and time-consuming with potential impurities
Solution Approach 1:
The patent combines multiple separate steps (graphene production, functionalization, and composite fabrication) into a single integrated process where layered materials are exfoliated directly within the elastomer precursor matrix, eliminating the need for separate purification and functionalization steps while maintaining conductive properties
Solution Approach 2:
The patent performs exfoliation of layered materials directly within the elastomer precursor before curing, ensuring uniform distribution and proper functionalization occurs in advance, which simplifies the overall production process and reduces the risk of impurities
2Ease of manufacture
If conventional mixing methods are used to combine graphene with elastomers, then the composites can be fabricated, but inhomogeneous mixtures and agglomeration occur
Solution Approach 1:
The patent uses the elastomer precursor as an intermediary medium that facilitates uniform exfoliation and distribution of layered materials throughout the matrix, preventing agglomeration while enabling easy fabrication through a single mixing and curing process
Solution Approach 2:
The patent changes the physical state and properties of the elastomer to a precursor form that allows better penetration and uniform distribution of exfoliated nanoparticles, achieving homogeneous mixtures that maintain flexibility and processability
3Ease of manufacture
If solution-processed graphene electrodes are used, then the composites can be formed, but structural defects occur due to oxidation/reduction process
Solution Approach 1:
The patent extracts and eliminates the problematic oxidation/reduction step from the process by using direct mechanical or shear-induced exfoliation of layered materials within the elastomer precursor, avoiding structural defects while maintaining ease of manufacture
Solution Approach 2:
The patent uses readily available layered materials (such as graphite or clay) that can be easily exfoliated and discarded after serving their function as fillers, avoiding the need for complex, defect-prone graphene synthesis processes
4Productivity
If melt processing is used to produce G-EMCs, then commercialization potential increases, but poor dispersion and material degradation occur
Solution Approach 1:
The patent changes the processing parameters by working with elastomer precursors at lower viscosities and temperatures before curing, enabling superior dispersion of nanoparticles without the high shear and temperature conditions that cause material degradation in conventional melt processing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Produces flexible, conductive elastomeric nanocomposites suitable for various sensors, including health monitoring and temperature sensing, with reduced production time and cost, and enhanced performance due to superior nanoparticle-matrix bonding.
Implementation Method 1
blending the elastomer polymer precursor and at least one layered material under shear sufficient to exfoliate the layered material in the elastomer polymer precursor until 2D nanoparticles are formed
Implementation Method 2
When the filler content is above the percolation threshold in the composite, electrons tunnel or hop from one graphene flake to another; therefore, the change in distance between graphene flakes changes the resistance to electron flow
Implementation Method 3
Elastomers are thermoset polymers, which are highly viscoelastic in nature, that are formed by combining precursors, including the elastomer precursor and curing agent, to induce polymerization and curing
Data Source
AI summary
Disclosed is a concise, inexpensive and scalable method for preparing elastomers filled with conductive 2D nanoparticles. The method comprises independently filling elastomer polymer precursors and/or corresponding elastomer polymer curing agents or their precursors with conductive 2D nanoparticles by shear exfoliation of a layered material, followed by mixing the two components and curing to form the elastomer. Such filled elastomers have utility in preparing various types of sensors which are useful in a variety of practical applications and devices.