Role,effect, and influences of micro and nano‐fillers on various properties of polymer matrix composites for microelectronics: A review

Ever since the discovery of polymer composites, its potential has been anticipated for numerous applications in various fields such as microelectronics, automobiles, and industrial applications. In this paper, we review filler reinforced polymer composites for its enormous potential in microelectronic applications. The interface and compatibility between matrix and filler have a significant role in property alteration of a polymer nanocomposites. Ceramic reinforced polymeric nanocomposites are promising candidate dielectric materials for several micro‐ and nano‐electronic devices. Because of its synergistic effect like high thermal conductivity, low thermal expansion, and dielectric constant of ceramic fillers with the polymer matrix, the resultant nanocomposites have high dielectric breakdown strength. The thermal and dielectric properties are discussed in the view of filler alignment techniques and its effect on the composites. Furthermore, the effect of various surface modified filler materials in polymer matrix, concepts of network forming using filler, and benefits of filler alignment are also discussed in this work. As a whole, this review article addresses the overall view to novice researchers on various properties such as thermal and dielectric properties of polymer matrix composites and direction for future research to be carried out.     

Elastomer Nanocomposite; Properties

Polymer nanocomposites represent a class of materials that have assumed great importance in recent years and are the focus of extensive research. Unlike plastomer nanocomposites, the elastomer nanocomposites are in the stage of infancy in respect to their applications.

In general, in polymer composites, the matrix and the filler are bonded to each other by weak intermolecular forces and covalent bonding are rarely involved. If the filler could be dispersed in the polymer matrix at the nanometre level and is able to interact with the matrix by chemical bonding, nanocomposites with significant properties improvement are obtained. These improvements can include mechanical properties (module, strength, etc.), thermal resistance, decrease in gas permeability (barrier), flammability, etc.

This paper is a review of the property improvements of different elastomers using nanofillers like silicates, carbon black, metallic powders, cellulose crystals, mixture of nanofillers, etc, with the intention of obtaining elastomer nanocomposites.     

An overview of boron nitride based polymer nanocomposites

Recently, boron nitride (BN) based materials have received significant attention in both academic and industrial sectors due to its interesting properties like large energy band gap, good resistance to oxidation, excellent thermal conductivity, thermal stability, chemical inertness, significant mechanical property and widespread applications. This review article deals with the preparation and properties of boron nitride and its nanocomposites with various polymers. Diverse polymers have been explored for the preparation of boron nitride filled polymer nanocomposites by adopting different mixing methods. Properties of the resulting polymer nanocomposites mainly depend up on filler size and dispersion, mixing conditions and type of interaction between polymer matrix and the filler. Herein, the structure, preparation and properties of various boron nitride based polymer nanocomposites are reviewed in detail along with a brief overview of different classes of BN nanomaterials.     

Dielectric,mechanical and electro-stimulus response properties studies of polyurethane dielectric elastomer modified by carbon nanotube-graphene nanosheet hybrid fillers

The typical nano-carbon materials, 1D fiber-like carbon nanotubes (CNTs) and 2D platelet-like graphene nanosheets (GRNs), that have attracted tremendous attention in the field of polymer nanocomposites due to their unprecedented properties, are used as conducting filler to induce a considerable improvement in the mechanical, thermal and electrical properties of the resulting graphene/polymer nanocomposites at very low loading contents. This study deals with the preparation and electro-stimulus response properties of polyurethane (PU) dielectric elastomer films with such 1D and 2D nanocarbon fillers embedded in the polymer matrix. The various forms of carbon used in composite preparation include CNT, GRN and CNT-GRN hybrid fillers. Results indicate that the dielectric, mechanical and electromechanical properties depend on the carbon filler type and the carbon filler weight fraction. Here, it has been also established that embedding CNT-GRN hybrid fillers into pristine polyurethane endows somewhat better dispersion of CNTs and GRNs as well as better interfacial adhesion between the carbon fillers and matrix, which results in an improvement in electric-induced strain. Therefore, the nanocomposites seem to be very attractive for microelectromechanical systems applications.     

Rheological properties of cellulose nanocrystal-embedded polymer composites: a review

Nanotechnology provides useful insights into the behavioural properties of materials from the nanoscale point of view, enabling researchers to develop new materials that were previously inconceivable. Cellulose is an ideal candidate for nanomaterial for nanotechnology because of its nanofibrillar structure, abundance, renewability, biodegradability and eco-friendly nature. Nanocrystalline cellulose materials have become the focus many studies related to these materials and their applications. This review summarises the current knowledge on the field of nanomaterials, focussing mainly on the rheological behaviour of polymer nanocomposites embedded with nanocrystalline cellulose. This review will enable better understanding of the use of nanocrystalline cellulose for the development and applications of cellulose nanocrystal-based nanocomposites.     

Lignin nanocomposites

Lignin is a biopolymer and one of the main constituents of woody plants where it plays the role of lining agent and is comparable in this respect to cement in steel reinforced concrete. Polymer nanocomposites containing biopolymers such as cellulose, lignin, starch, proteins, etc. are the object of recent numerous studies and are known also as bio-nanocomposites. This paper deals with lignin use in various polymer nanocomposites. It presents the preparation and uses of nanolignin as a filler and lignin uses as a matrix or a matrix component in polymer nanocomposites.     

Polymer Nanocomposites in Sensor Applications: A Review on Present Trends and Future Scope

Polymers are crucial constituents of modern electronic devices. They can be used in their pristine, composite or nanocomposite forms for several domestic and industrial applications with innumerable unique possibilities. Polymer nanocomposites have gained wide theoretical interest and numerous practical applications in diverse fields of science and technology as they bestow the materials not only with virtuous processability but also with exceptional functionalities. It is evidenced that the electrical conductance of polymer nanocomposite is governed by the conductive filler networks within the polymer matrix. Hence, insignificant variation in the conductive networks can result in noteworthy variations in the output electric signal of polymer nanocomposite. Exploiting this stimuli-responsive performance of conductive networks to the physical parameters, polymer nanocomposites can be harnessed to fabricate novel sensitive sensors to detect vital physical parameters viz.strain/stress, pressure, temperature, solvent or vapor. Technical and phenomenological studies on polymer nanocomposites are still enduring.Advanced explanations are being sought but the mechanisms governing the formation of several polymer nanocomposites are still topics of debate in the material science community. Their in-depth investigation requires copious scientific work. This review analytically sketches the synthesis, microstructures, physiochemical properties and the underlying mechanisms for stimuli-responsiveness to the physical parameters of the polymer nanocomposites as well as their applications in various sensitive sensors and detectors. Thus, it became evocative for this review to focus on their processing methodologies, physiochemical physiognomies, classification and probable potentials of polymer nanocomposites.This review primarily presents the current literature survey on polymer composites and the gap areas in the study encourages the objective of the present review article. Finally, the status, perspectives and the advantages of specific polymer nanocomposites at present are summarized. The attention of this review is drawn to the present trends, challenges and future scope in this field of study. Finally, the vital concern and future challenge in utilizing the stimulus responsive behavior of polymer nanocomposites to design versatile sensors for real time applications are elaborately discussed.     

Properties of ultrahighly filled composites based on polymers and ground rubber

The stress-strain and strength properties of ultrahighly filled composites based on thermoplastic polymers and ground rubber wastes are studied. The content of the elastic filler is higher than 70 wt%. As is shown, introduction of minor amounts of the plastic polymer, which serves as the binder for the filler particles, makes it possible to improve the strength properties of ultrahighly filled composites and to prepare materials of a desired thickness. A correlation between the stress-strain properties of the plastic polymer-rubber systems and the effective viscosity of the matrix polymer is established. When a polymer with homogeneous deformation and good adhesion to the elastic filler is used as the matrix, the resultant composites are characterized by properties close to those of vulcanized rubbers. A new method is proposed for processing of ground rubber wastes and preparation of materials that are similar to hard rubbers.     

Structure and mechanical properties of thermoplastics modified with nanodiamonds

The structure and properties of composite materials based on amorphous thermoplastics and detonation nanodiamonds are studied. The conception of the “rheological method” is advanced for compatibilization of a polymer and a filler under the regime of elastic turbulence (spurt) for preparation of composites with a high level of dispersion and a homogeneous distribution of nanodiamond particles. As a rule, the dependences of strength and physicomechanical characteristics of the nanocomposites on the content of the dispersed phase are described by curves with an extremum or saturation. The concentration of the filler corresponding to the extremum or the approach to the plateau value for a specific parameter depends on the nature of the polymer matrix and is attained at filler contents below 2.5 wt %. The elastic modulus monotonically increases as the content of nanodiamonds is increased to 5 wt %.     

Thermal behaviour of compatibilised polypropylene nanocomposite: Effect of processing conditions

The thermal properties and fire behaviour of polypropylene (PP) nanocomposites were investigated using differential scanning calorimetry, dynamic-mechanical analysis, thermogravimetric analysis and glow wire test. In order to study the morphological structure of the materials obtained, TEM and XRD analyses were also carried out. The nanocomposites were prepared using the melt intercalation technique in a co-rotating intermeshing twin screw extruder. Particular attention was given to studying the influence of different processing conditions (barrel temperature profile and screw rate) and compositions of PP-nanoclay blends (clay content, use of compatibiliser) on the thermal properties of the nanocomposites.The results show that all the properties analysed were strongly influenced by the nanocomposite composition; instead, the processing conditions greatly affect only the dynamic-mechanical properties. DSC curves show that the crystallinity is deeply influenced by the presence of the clay in the matrix, owing to the fact that the filler acts as nucleating agent. DMA curves show that materials processed at low temperature profile and high shear stress, i.e. when a good clay dispersion is achieved, are characterised by an enhanced modulus, thus indicating that the incorporation of clay into the PP matrix remarkably enhances its stiffness and has good reinforcing effects. TGA traces in oxidizing atmosphere show a drastic shift of the weight loss curve towards higher temperature and no variation of the onset temperature (i.e. the temperature at which degradation begins). The TGA analyses in inert atmosphere show instead marked increase of this parameter (about 200 °C) and no shift of weight loss curves. Glow wire results highlight that polymer nanocomposites are characterised by enhanced fire behaviour.     

Polysaccharide-based natural and synthetic nanocomposites

Modern concepts on the supramolecular organization of natural nanocomposite materials based on structural polysaccharides are discussed, beginning from the stage of biosynthesis. The methods for obtaining nanocrystals and nanofibrils of cellulose and chitin, as well as their structure and properties, are discussed. Various methods for the synthesis of nanocomposites with the use of water-soluble, water-dispersed, and hydrophobic polymer matrixes are described. Special attention is given to surmounting the incompatibility of polymer and polysaccharide particles.     

Mechanical,thermal and barrier properties of pectin/cellulose nanocrystal nanocomposite films and their effect on the storability of strawberries (Fragaria ananassa)

In this work, two formulations of pectin/cellulose nanocrystals/glycerol nanocomposites were employed as packaging to extend storage life of strawberries. The effects of incorporating cellulose nanocrystals extracted from bleached Kraft wood pulp on the mechanical, thermal, and barrier properties of pectin‐based nanocomposites were evaluated. Nanocomposite films with different filler levels of cellulose nanocrystals (1, 2, 4 and 8% w/w) were prepared by casting. Compared with the neat film of pectin, improvements in the mechanical properties of the nanocomposites were observed, but these films became fragile. To improve the film flexibility, glycerol was added as a plasticizer and then new variations in the mechanical, thermal, and barrier properties of these nanocomposites were evaluated. The effects of nanocomposite films on storability of strawberries were compared with Poly vinyl chloride packaging films. The Poly vinyl chloride film and the nanocomposites showed similar behavior regarding weight loss by the strawberries, especially in the initial days of storage. The results show that pectin/cellulose nanocrystals/glycerol nanocomposites could be considered as a viable packaging alternative for replaced the Poly vinyl cloride film. Copyright © 2015 John Wiley & Sons, Ltd.     

The Impact of Filler Geometry on Polylactic Acid-Based Sustainable Polymer Composites

Recently, biocomposites have emerged as materials of great interest to the scientists and industry around the globe. Among various polymers, polylactic acid (PLA) is a popular matrix material with high potential for advanced applications. Various particulate materials and nanoparticles have been used as the filler in PLA based matrix. One of the extensively studied filler is cellulose. However, cellulose fibres, due to their hydrophilic nature, are difficult to blend with a hydrophobic polymer matrix. This leads to agglomeration and creates voids, reducing the mechanical strength of the resulting composite. Moreover, the role of the various forms of pure cellulose and its particle shape factors has not been analyzed in most of the current literature. Therefore, in this work, materials of various shapes and shape factors were selected as fillers for the production of polymer composites using Polylactic acid as a matrix to fill this knowledge gap. In particular, pure cellulose fibres (three types with different elongation coefficient) and two mineral nanocomponents: precipitated calcium carbonate and montmorillonite were used. The composites were prepared by a melt blending process using two different levels of fillers: 5% and 30%. Then, the analysis of their thermomechanical and physico-chemical properties was carried out. The obtained results were presented graphically and discussed in terms of their shape and degree of filling.     

Effect of the C/O ratio in graphene oxide materials on the reinforcement of epoxy-based nanocomposites

The effect of the C/O ratio of graphene oxide materials on the reinforcement and rheological percolation of epoxy-based nanocomposites has been studied. As-prepared graphene oxide (GO) and thermally-reduced graphene oxide (TRGO) with higher C/O ratios were incorporated into an epoxy resin matrix at loadings from 0.5 to 5 wt %. Tensile testing revealed good reinforcement of the polymer up to optimal loadings of 1 wt %, whereas agglomeration of the flakes at higher loadings caused the mechanical properties of the composites to deteriorate. The level of reduction (C/O) of the graphene oxide filler was found to influence the mechanical and rheological properties of the epoxy composites. Higher oxygen contents were found to lead to stronger interfaces between graphene and epoxy, giving rise to higher effective Young's moduli of the filler and thus to superior mechanical properties of the composite. The effective modulus of the GO in the nanocomposites was found to be up to 170 GPa. Furthermore, rheological analysis showed that highly oxidized graphene flakes did not raise the viscosity of the epoxy resin significantly, facilitating the processing considerably, of great importance for the development of these functional polymeric materials. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2016, 54, 281–291     

Real Time Monitoring of Morphologic and Mechanical Properties of Polymer Nanocomposites During Extrusion by near Infrared and Ultrasonic Spectroscopy

Extrusion is one of the most applied technologies for the processing of polymer nanocomposites for applications in automotive, electrical and packaging industrial sectors. These nanostructured materials have advantages in comparison to traditional polymer materials, so that properties like tensile strength and modulus, barrier and surface properties, electrical properties and flame retardancy will be improved. There is a need to control amount and dispersion of the nanofillers in the polymer matrix during melt processing and to control the influence of the processing conditions on the nanocomposite formation. For an adequate real time characterization it is necessary to measure directly in the extruder. Spectroscopic methods and Ultrasonic measurements are outstanding methods for this kind of in-line monitoring. This paper deals with the real time determination of the dispersion and the impact strength of polymer nanocomposites in the melt during extrusion by Ultrasonic measurements and NIR spectroscopy. These in-line measurements were correlated with off-line rheological measurements, transmission electron microscopy and mechanical test measurements by multivariate data analysis. The polymers used are polypropylene and polyamide 6. As nanofillers we used different modified layered silicates. We determined the degree of exfoliation as an indicator for the dispersion of the nanofiller in the polymer matrix for different layered silicates and at different process conditions.     

Depth-Dependent Indentation Microhardness Studies of Different Polymer Nanocomposites

Continuous depth sensing indentation microhardness measurements were performed to investigate the effect of filler content and dimensionality on the mechanical behaviour of different polymer nanocomposites. In 1D filler reinforced nanocomposites (such as PP/MWCNT system), both the hardness and the indentation modulus were found to appreciably increase up to a filler weight fraction of 1.6 wt.-%. Further addition of the filler changed the properties only insignificantly. In the nanocomposites with 2D filler (such as in PA6/LS) both the hardness and the indentation modulus increase notably with the addition of the filler and showed intense plasticity. In the investigated systems and composition range, the 3D filler (such as PP/OS2) showed no reinforcing effect at all. In was concluded that the 1D and 2D nanofillers play much more effective reinforcing role to improve the mechanical properties than the 3D fillers.     

Polymer matrix influence on stability of wood polymer composites

The aim of the presented work is to show the influence of the various polymer matrices and the different amounts of the cellulose filler on the composites properties. Samples based on polypropylene, polystyrene, polyoxymethylene, acrylonitrile butadiene styrene, polyester resin, and polylactic acid with different contents of cellulose fibers were prepared by injection molding process. The mechanical and dielectric properties of these composites were studied in order to check whether investigated wood polymer composites fulfill requirements for their application in electrical devices. For all tested composites, a linear increase of modulus with cellulose content was observed. Addition of cellulose to the tested polymers significantly reduces strain at break. In the case of polypropylene and polyoxymethylene composites, the tensile strength increases with the content of the filler. For other materials, there is an inverse relationship, namely the addition of cellulose decreases the tensile strength. The electrical strength decrease was observed with increased cellulose content for the majority of the investigated composites. Polar groups incorporated by cellulose fibers have led to dielectric constant increase. Furthermore, aging of composites in mineral oil and evaluation of water uptake for wood–plastic samples were performed. Wood polymer composites have changed significantly after aging. The water diffusion coefficients were determined, and the significant influence of the amount of cellulose on the water absorption was shown. Copyright © 2015 John Wiley & Sons, Ltd.     

Decoupling the effects of screw speed and particle surface functionality on the filler suspension state in PBS/fumed silica nanocomposites

This work assessed the relative effects of processing conditions and interfacial interactions on the structure and properties of PBS/fumed silica nanocomposites. Rheology and scattering were used to investigate the dispersion state of silica particles with different surface treatments in nanocomposites produced by ultra‐high speed twin‐screw extrusion. Structural parameters of the silica, such as fractal dimension and Fisher exponent, were estimated by low‐frequency rheology responses and lower q scattering data. This study demonstrates that both decreased bulk polymer properties and improved filler suspension caused by high shear compounding determine the final properties of these PBS based nanocomposites. While the molecular weight of bulk polymer matrix was significantly reduced, the extreme shear increased the probability of forming percolated clusters, leading to remarkable reinforcement (up to 4000%) as evidenced by the low‐frequency rheological response. Further, the improvement in dispersion was enhanced when the filler was functionalized with a compatibilizing surface treatment. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2016 , 54, 1820–1828     

Ethylene-vinyl acetate (EVA)/polycaprolactone (PCL)–Fe3O4 composites

In this study, we investigate the effect of nano sized Fe₃O₄ nanoparticles on the mechanical and thermal properties of EVA/PCL–Fe₃O₄ composites. Composites were prepared using the melt mixing technique on a Rheomex mixer coupled to a single screw extruder. The fine dispersion of nano-Fe₃O₄ aggregates in the polymer matrices led to a significant improvement in the crystallinity, thermal and mechanical properties of EVA/PCL–Fe₃O₄ nanocomposites compared to that of native polymers due to improved interface bonding between the filler and the polymer matrix. Techniques such as scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and Instron for mechanical properties were used to characterize nanocomposites samples. The results obtained from this investigation demonstrated that composite materials could be promising raw materials in industry.