Total conversion from graphite to few-layer graphene nanocomposite

Abstract Graphene promises to revolutionize the plastic market, providing extra-properties to polymer composites. However, the commercialization process is seriously hindered by low-yield exfoliation and a large amount of waste liquid generated during fabrication process. Herein, we report total conversion from graphite to few-layer graphene nanocomposite with zero waste. Flake graphite is directly exfoliated by bead milling into few-defect, few-layer graphene with a yield of 100% in polymer monomers at an ultrahigh concentration of up to 4 wt% (≈ 40 mg/mL), followed by in situ bulk polymerization into few-layer graphene nanocomposite. The graphene nanosheets constitute a three-dimensional jammed network within the nanocomposite, and thus bring significant enhancement in modulus (2.6 times), electrical conductivity (12 orders of magnitude) and thermal conductivity (1 order of magnitude), as compared to pure polymer material. This strategy opens a promising avenue for low-cost, environmental-friendly fabrication of graphene-containing polymer nanocomposites with improved mechanical and functional properties.