Characterizations of expanded graphite/polymer composites prepared by in situ polymerization

Poly(styrene-co-acrylonitrile)/expanded graphite composite sheets with very low in-plane (8.5 x 10(-3) Omegacm) and through-thickness (1.2 x 10(-2) Omegacm) electrical resistivities have been prepared. The expanded graphite was made by oxidation of natural graphite flakes, followed by thermal expansion at 600 degreesC. Microscopic results disclosed that the expanded graphite has a legume-like structure, and each "legume" has a honeycomb sub-structure with many diamond-shaped pores. After soaking the expanded graphite with styrene and acrylonitrile monomers, the polymer/expanded graphite composite granules were obtained by in situ polymerization of the monomers inside the pores at 80 degreesC. The functional groups and microstructures of the oxidized graphite, expanded graphite and composites in the forms of particles or sheets were carefully characterized using various techniques, including X-ray powder diffraction, thermogravimetry, optical and electron microscopy. It was found that the honeycomb sub-structure survived after hot-pressing, resulting in a graphite network penetrating through the entire composite body, which produces a composite with excellent electrical conductivity. (C) 2004 Elsevier Ltd. All rights reserved.