Breaking through the Solid/Liquid Processability Barrier: Thermal Conductivity and Rheology in Hybrid Graphene-Graphite Polymer Composites

Thermal conductivity (TC) enhancement of an insulating polymer matrix at low filler concentration is possible through the loading of a high aspect ratio, thermally conductive single filler. Unfortunately, the dispersion of high-aspect-ratio particles greatly influences the rheological behavior of the polymer host at relatively low volume fractions, which makes further polymer processing or mixing difficult. A possible remedy is using two (hybrid) fillers, differing in their aspect ratios: (1) a plate-like filler, which sharply increases both viscosity and TC, and (2) an isotropic filler, which gradually increases these properties. We examine this hypothesis in a thermosetting silicone rubber by loading it with different ratios, (1)/(2), of graphene nanoplatelets (GNPs) (1) and graphite powder (2). We constructed a “phase diagram” delineating two composite processability regions: solid-like (moldable) or fluid-like (pourable). This diagram may be employed to tailor the mixture’s viscosity to a desired TC v...