Highly Sensitive,Wearable, Durable Strain Sensors and Stretchable Conductors Using Graphene/Silicon Rubber Composites

Highly sensitive, wearable and durable strain sensors are vital to the development of health monitoring systems, smart robots and human machine interfaces. The recent sensor fabrication progress is respectable, but it is limited by complexity, low sensitivity and unideal service life. Herein a facile, cost‐effective and scalable method is presented for the development of high‐performance strain sensors and stretchable conductors based on a composite film consisting of graphene platelets (GnPs) and silicon rubber. Through calculation by the tunneling theory using experimental data, the composite film has demonstrated ideal linear and reproducible sensitivity to tensile strains, which is contributed by the superior piezoresistivity of GnPs having tunable gauge factors 27.7–164.5. The composite sensors fabricated in different days demonstrate pretty similar performance, enabling applications as a health‐monitoring device to detect various human motions from finger bending to pulse. They can be used as electronic skin, a vibration sensor and a human‐machine interface controller. Stretchable conductors are made by coating and encapsulating GnPs with polydimethyl siloxane to create another composite; this structure allows the conductor to be readily bent and stretched with sufficient mechanical robustness and cyclability.     

Highly Conductive Nanocomposites with Three‐Dimensional,Compactly Interconnected Graphene Networks via a Self‐Assembly Process

Polymer‐based materials with high electrical conductivity are of considerable interest because of their wide range of applications. The construction of a 3D, compactly interconnected graphene network can offer a huge increase in the electrical conductivity of polymer composites. However, it is still a great challenge to achieve desirable 3D architectures in the polymer matrix. Here, highly conductive polymer nanocomposites with 3D compactly interconnected graphene networks are obtained using a self‐assembly process. Polystyrene (PS) and ethylene vinyl acetate (EVA) are used as polymer matrixes. The obtained PS composite film with 4.8 vol% graphene shows a high electrical conductivity of 1083.3 S/m, which is superior to that of the graphene composite prepared by a solvent mixing method. The electrical conductivity of the composites is closely related to the compact contact between graphene sheets in the 3D structures and the high reduction level of graphene sheets. The obtained EVA composite films with the 3D graphene structure not only show high electrical conductivity but also exhibit high flexibility. Importantly, the method to fabricate 3D graphene structures in polymer matrix is facile, green, low‐cost, and scalable, providing a universal route for the rational design and engineering of highly conductive polymer composites.     

Simultaneous Electrochemical Dual‐Electrode Exfoliation of Graphite toward Scalable Production of High‐Quality Graphene

Developing scalable methods to produce large quantities of high‐quality and solution‐processable graphene is essential to bridge the gap between laboratory study and commercial applications. Here an efficient electrochemical dual‐electrode exfoliation approach is developed, which combines simultaneous anodic and cathodic exfoliation of graphite. Newly designed sandwich‐structured graphite electrodes which are wrapped in a confined space with porous metal mesh serve as both electrodes, enabling a sufficient ionic intercalation. Mechanism studies reveal that the combination of electrochemical intercalation with subsequent thermal decomposition results in drastic expansion of graphite toward high‐efficiency production of graphene with high quality. By precisely controlling the intercalation chemistry, the two‐step approach leads to graphene with outstanding yields (85% and 48% for cathode and anode, respectively) comprising few‐layer graphene (1–3 layers, >70%), ultralow defects (I_D/I_G < 0.08), and high production rate (exceeding 25 g h^?1). Moreover, its excellent electrical conductivity (>3 × 10⁴ S m^?1) and great solution dispersibility in N‐methyl pyrrolidone (10 mg mL^?1) enable the fabrication of highly conductive (11 Ω sq^?1) and flexible graphene films by inkjet printing. This simple and efficient exfoliation approach will facilitate the development of large‐scale production of high‐quality graphene and holds great promise for its wide application.     

Seriography‐Guided Reduction of Graphene Oxide Biopapers for Wearable Sensory Electronics

Novel nacre‐mimic bio‐nanocomposites, such as graphene‐based laminates, are pushing the boundaries of strength and toughness as flexible engineering materials. Translating these material advances to functional flexible electronics requires methods for generating print‐scalable microcircuits (conductive elements surrounded by dielectric) into these strong, tough, lightweight bio‐nanocomposites. Here, a new paradigm for printing flexible electronics by employing facile, eco‐friendly seriography to confine the reduction of graphene oxide biopapers reinforced by silk interlayers is presented. Well‐defined, micropatterned regions on the biopaper are chemically reduced, generating a 10⁶ increase in conductivity (up to 10⁴ S m^?1). Flexible, robust graphene‐silk circuits are showcased in diverse applications such as resistive moisture sensors and capacitive proximity sensors. Unlike conductive (i.e., graphene‐ or Ag nanoparticle‐loaded) inks printed onto substrates, seriography‐guided reduction does not create mechanically weak interfaces between dissimilar materials and does not require the judicious formation of ink. The unimpaired functionality of printed‐in graphene‐silk microcircuits after thousands of punitive folding cycles and chemical attack by harsh solvents is demonstrated. This novel approach provides a low‐cost, portable solution for printing micrometer‐scale conductive features uniformly across large areas (>hundreds of cm²) in layered composites for applications including wearable health monitors, electronic skin, rollable antennas, and conformable displays.     

Toughness and Fracture Properties in Nacre‐Mimetic Clay/Polymer Nanocomposites

Nacre inspires researchers by combining stiffness with toughness by its unique microstructure of aligned aragonite platelets. This brick‐and‐mortar structure of reinforcing platelets separated with thin organic matrix has been replicated in numerous mimics that can be divided into two categories: microcomposites with aligned metal oxide microplatelets in polymer matrix, and nanocomposites with self‐assembled nanoplatelets—usually clay or graphene oxide—and polymer. While microcomposites have shown exceptional fracture toughness, current fabrication methods have limited nacre‐mimetic nanocomposites to thin films where fracture properties remained unexplored. Yet, fracture resistance is the defining property of nacre, therefore centrally important in any mimic. Furthermore, to make use of these properties in applications, bulk materials are required. Here, up to centimeter‐thick nacre‐mimetic clay/polymer nanocomposites are produced by the lamination of self‐assembled films. The aligned clay nanoplatelets are separated by poly(vinyl alcohol) matrix, with 10⁶–10⁷ nanoplatelets on top of each other in the bulk plates. Fracture testing shows crack deflection and a fracture toughness of 3.4 MPa m^1/2, not far from nacre. Flexural tests show high stiffness (25 GPa) and strength (220 MPa) that, despite the hydrophilic constituents, are not substantially affected by exposure to humidity.     

Inkjet Printed Large‐Area Flexible Few‐Layer Graphene Thermoelectrics

Graphene‐based organic nanocomposites have ascended as promising candidates for thermoelectric energy conversion. In order to adopt existing scalable printing methods for developing thermostable graphene‐based thermoelectric devices, optimization of both the material ink and the thermoelectric properties of the resulting films are required. Here, inkjet‐printed large‐area flexible graphene thin films with outstanding thermoelectric properties are reported. The thermal and electronic transport properties of the films reveal the so‐called phonon‐glass electron‐crystal character (i.e., electrical transport behavior akin to that of few‐layer graphene flakes with quenched thermal transport arising from the disordered nanoporous structure). As a result, the all‐graphene films show a room‐temperature thermoelectric power factor of 18.7 µW m^?1 K^?2, representing over a threefold improvement to previous solution‐processed all‐graphene structures. The demonstration of inkjet‐printed thermoelectric devices underscores the potential for future flexible, scalable, and low‐cost thermoelectric applications, such as harvesting energy from body heat in wearable applications.     

Flexible Solid‐State Supercapacitors with Enhanced Performance from Hierarchically Graphene Nanocomposite Electrodes and Ionic Liquid Incorporated Gel Polymer Electrolyte

High energy density, durability, and flexibility of supercapacitors are required urgently for the next generation of wearable and portable electronic devices. Herein, a novel strategy is introduced to boost the energy density of flexible soild‐state supercapacitors via rational design of hierarchically graphene nanocomposite (GNC) electrode material and employing an ionic liquid gel polymer electrolyte. The hierarchical graphene nanocomposite consisting of graphene and polyaniline‐derived carbon is synthesized as an electrode material via a scalable process. The meso/microporous graphene nanocomposites exhibit a high specific capacitance of 176 F g^?1 at 0.5 A g^?1 in the ionic liquid 1‐ethyl‐3‐methylimidazolium tetrafluoroborate (EMIBF₄) with a wide voltage window of 3.5 V, good rate capability of 80.7% in the range of 0.5–10 A g^?1 and excellent stability over 10 000 cycles, which is attributed to the superior conductivity (7246 S m^?1), and quite large specific surface area (2416 m² g^?1) as well as hierarchical meso/micropores distribution of the electrode materials. Furthermore, flexible solid‐state supercapacitor devices based on the GNC electrodes and gel polymer electrolyte film are assembled, which offer high specific capacitance of 180 F g^?1 at 1 A g^?1, large energy density of 75 Wh Kg^?1, and remarkable flexible performance under consecutive bending conditions.     

Sandwich‐Type Nanocomposite of Reduced Graphene Oxide and Periodic Mesoporous Silica with Vertically Aligned Mesochannels of Tunable Pore Depth and Size

Sandwich‐type nanocomposites of graphene oxide (GO) and periodic mesoporous silica (PMS) with vertically aligned mesochannels of different pore depth and size are synthesized and characterized, and their formation modes are examined. The existence of mesoscale ordered structure in the mixture of GO and surfactant solutions is confirmed for the first time by in situ small angle X‐ray scattering measurement using synchrotron radiation. The mesochannel depth and pore wall ripening of PMS in the nanocomposites are controlled by the reaction time of the hydrolysis of tetraethyl orthosilicate. The pore size of PMS in the nanocomposites can be varied in the range of 1–5 nm by varying the chain length of alkyltrimethylammonium (C_n TA⁺) template and high specific surface area (≈1000 m² g^?1) is achieved for all samples. Nanocomposites with vertically aligned PMS mesochannels can be synthesized by applying C_n TA⁺ templates of n ≥ 12, whereas with C_n TA⁺ of n ≤ 10, either PMS nanoparticle deposited GO structure or the structure with incomplete coverage of GO surface with imperfect PMS is found. The aggregation behaviors of surfactant molecules on GO depend on surfactant concentration relative to critical micelle concentration and reaction temperature, and result in the peculiar nanocomposites of different structural styles.     

Highly Conductive Transition Metal Carbide/Carbonitride(MXene)@polystyrene Nanocomposites Fabricated by Electrostatic Assembly for Highly Efficient Electromagnetic Interference Shielding

Highly conductive polymer nanocomposites are greatly desired for electromagnetic interference (EMI) shielding applications. Although transition metal carbide/carbonitride (MXene) has shown its huge potential for producing highly conductive films and bulk materials, it still remains a great challenge to fabricate extremely conductive polymer nanocomposites with outstanding EMI shielding performance at minimal amounts of MXenes. Herein, an electrostatic assembly approach for fabricating highly conductive MXene@polystyrene nanocomposites by electrostatic assembling of negative MXene nanosheets on positive polystyrene microspheres is demonstrated, followed by compression molding. Thanks to the high conductivity of MXenes and their highly efficient conducting network within polystyrene matrix, the resultant nanocomposites exhibit not only a low percolation threshold of 0.26 vol% but also a superb conductivity of 1081 S m^?1 and an outstanding EMI shielding performance of >54 dB over the whole X‐band with a maximum of 62 dB at the low MXene loading of 1.90 vol%, which are among the best performances for electrically conductive polymer nanocomposites by far. Moreover, the same nanocomposite has a highly enhanced storage modulus, 54% and 56% higher than those of neat polystyrene and conventional MXene@polystyrene nanocomposite, respectively. This work provides a novel methodology to produce highly conductive polymer nanocomposites for highly efficient EMI shielding applications.     

Scalable Production of Edge‐Functionalized Graphene Nanoplatelets via Mechanochemical Ball‐Milling

Although there are a variety of methods for producing graphene, commercialization remains challenging because each method has its own pros and cons. For the wide use of graphene as a next generation material in diverse applications, the process by which graphene is manufactured must be robust enough to overcome barriers to commercialization, as has been experienced in commercializing carbon nanotube products. Here, a recent discovery of a new manufacturing process for efficient delamination of graphite into graphene nanoplatelets (GnPs) via mechanochemical ball‐milling is summarized. In this process, transferring sufficient kinetic energy to graphitic frameworks will crack graphitic C–C bonds, generate active carbon species (mostly carbon free radicals), introduce edge‐functional groups, and delaminate graphitic layers into edge‐functionalized GnPs (EFGnPs). While this process is a method for mass production, it does not involve hazardous chemicals (e.g., corrosive acids and toxic reducing agents) such as those used for producing graphene oxide (GO) and reduced graphene oxide (rGO). Owing to its edge‐selective functionalization, the EFGnPs have minimal basal area defects with selectivity of a variety of edge groups by forming edge C–X bonds (X = nonmetals or metalloids) that are tunable.     

Stiff and Transparent Multilayer Thin Films Prepared Through Hydrogen‐Bonding Layer‐by‐Layer Assembly of Graphene and Polymer

Due to their exceptional orientation of 2D nanofillers, layer‐by‐layer (LbL) assembled polymer/graphene oxide thin films exhibit unmatched mechanical performance relative to any conventionally produced counterparts with similar composition. Unprecedented mechanical property improvement, by replacing graphene oxide with pristine graphene, is demonstrated in this work. Polyvinylpyrrolidone‐stabilized graphene platelets are alternately deposited with poly(acrylic acid) using hydrogen bonding assisted LbL assembly. Transmission electron microscopy imaging and the Halpin‐Tsai model are used to demonstrate, for the first time, that intact graphene can be processed from water to generate polymer nanocomposite thin films with simultaneous parallel‐alignment, high packing density, and exfoliation. A multilayer thin film with only 3.9 vol% of highly exfoliated, and structurally intact graphene, increases the elastic modulus (E) of a polymer multilayer thin film by 322% (from 1.41 to 4.81 GPa), while maintaining visible light transmittance of ≈90%. This is one of the greatest improvements in elastic modulus ever reported for a graphene‐filled polymer nanocomposite with a glassy (E > 1 GPa) matrix. The technique described here provides a powerful new tool to improve nanocomposite properties (mechanical, gas transport, etc.) that can be universally applied to a variety of polymer matrices and 2D nanoplatelets.     

Graphene Platelets and Their Polymer Composites: Fabrication,Structure, Properties,and Applications

Graphene oxide is extensively compounded with polymers toward a wide variety of applications. Less studied are few‐layer or multi‐layer highly crystalline graphene, both of which are herein named as graphene platelets. This article aims to provide the most recent advancements of graphene platelets and their polymer composites. A first focus lies on cost‐effective fabrication strategies of graphene platelets – intercalation and exfoliation – which work in a relative mass scale, e.g., 5.3 g h^?1. As no heavy oxidization is involved, the platelets have high crystalline integrity, e.g., C:O ratio over 8.0, with thicknesses 2–4 nm and lateral dimension up to a few micrometers. Through carefully selecting the solvent for dispersion and the molecules for surface modification, graphene platelets can be liquid‐processable, enabling them to be printed, coated, or compounded with various polymers. A purpose‐designed experiment is undertaken to unravel the effect of reasonable ultrasonication time on the platelet thickness. Typical polymer/graphene platelet composites are critically examined for their preparation, structure, and applications such as thermal management and flexible/stretchable electronic devices. Perspectives on the limitations, current challenges, and future prospects for graphene platelets and their polymer composites are provided.     

Edge‐Fluorinated Graphene Nanoplatelets as High Performance Electrodes for Dye‐Sensitized Solar Cells and Lithium Ion Batteries

Edge‐selectively fluorinated graphene nanoplatelets (FGnPs) are prepared by mechanochemically driven reaction between fluorine gas (20 vol% in argon) and activated carbon species from graphitic C–C bonds unzipped by high‐speed stainless steel balls with a high kinetic energy. The fluorination at edges of the unzipped graphene nanoplatelets (GnPs) is confirmed by various analytical techniques while the content of fluorine in FGnPs is determined to be 3.0 and 3.4 at% by X‐ray photoelectron spectroscopy and energy‐dispersive X‐ray spectroscopy, respectively. Because of the large difference in electronegativity between carbon (χ = 2.55) and fluorine (χ = 3.98) and the strong C–F bond, the edge‐fluorination of GnPs can provide the maximized charge polarization with an enhanced chemical stability. Thus, electrodes based on the resultant FGnPs demonstrate superb electrochemical performance with excellent stability/cycle life in dye‐sensitized solar cells (FF: 71.5%; J_sc: 14.44 mA cm^?2; V_oc: 970 mV; PCE: 10.01%) and lithium ion batteries (650.3 mA h g^?1 at 0.5 C, charge retention of 76.6% after 500 cycles).     

Insulator‐Conductor Type Transitions in Graphene‐Modified Silver Nanowire Networks: A Route to Inexpensive Transparent Conductors

Silver nanowire coatings are an attractive alternative to indium tin oxide for producing transparent conductors. To fabricate coatings with low sheet resistance required for touchscreen displays, a multi‐layer network of silver nanowires must be produced that may not be cost effective. This problem is counteracted here by modifying the electrical properties of an ultra‐low‐density nanowire network through local deposition of conducting graphene platelets. Unlike other solution‐processed materials, such as graphene oxide, our pristine graphene is free of oxygen functional groups, resulting in it being electrically conducting without the need for further chemical treatment. Graphene adsorption at inter‐wire junctions as well as graphene connecting adjacent wires contributes to a marked enhancement in electrical properties. Using our approach, the amount of nanowires needed to produce viable transparent electrodes could be more than 50 times less than the equivalent pristine high density nanowire networks, thus having major commercial implications. Using a laser ablation process, it is shown that the resulting films can be patterned into individual electrode structures, which is a pre‐requisite to touchscreen sensor fabrication.     

Large‐Area Ultrathin Graphene Films by Single‐Step Marangoni Self‐Assembly for Highly Sensitive Strain Sensing Application

Promoted by the demand for wearable devices, graphene has been proved to be a promising material for potential applications in flexible and highly sensitive strain sensors. However, low sensitivity and complex processing of graphene retard the development toward the practical applications. Here, an environment‐friendly and cost‐effective method to fabricate large‐area ultrathin graphene films is proposed for highly sensitive flexible strain sensor. The assembled graphene films are derived rapidly at the liquid/air interface by Marangoni effect and the area can be scaled up. These graphene‐based strain sensors exhibit extremely high sensitivity with gauge factor of 1037 at 2% strain, which represents the highest value for graphene platelets at this small deformation so far. This simple fabrication for strain sensors with highly sensitive performance of strain sensor makes it a novel approach to applications in electronic skin, wearable sensors, and health monitoring platforms.     

A Generic Conversion Strategy: From 2D Metal Carbides (MxCy) to M‐Self‐Doped Graphene toward High‐Efficiency Energy Applications

This study first presents a subtle thermal‐chlorination strategy for a universal transformation of abundant 2D metal carbides (M_xC_y, e.g., Cr₃C₂, Mo₂C, NbC, and VC) to 2D graphene and M‐self‐doped graphene (MG). The as‐obtained MG endows a transparent sheet architecture of one to four atomic layers. Simultaneously, MG with different M amounts is synthesized by tuning the chlorination parameters. Among them, the novel and representative Cr‐self‐doped graphene with optimal Cr amount (4.81 at%) demonstrates the outstanding electrochemical performance. It presents an energy density of 686 W h per kg electrode and a power density of more than 391 W per kg electrode as anode material of Li ion batteries, and four‐fold activity against the commercial iridium oxide electrode toward oxygen evolution reaction as well as a comparable oxygen reduction reaction performance to the commercial platinum catalyst. Moreover, this method is readily scalable to produce graphene and MG electrode materials on industrial levels.     

Integration of Stiff Graphene and Tough Silk for the Design and Fabrication of Versatile Electronic Materials

The production of structural and functional materials with enhanced mechanical properties through the integration of soft and hard components is a common approach to Nature's material design. However, directly mimicking these optimized design routes in the lab for practical applications remains challenging. For example, graphene and silk are two materials with complementary mechanical properties that feature ultrahigh stiffness and toughness, respectively. Yet, no simple and controllable approach is developed to homogeneously integrate these two components into functional composites, mainly due to the hydrophobicity and chemical inertness of graphene. In this study, well‐dispersed and highly stable graphene/silk fibroin (SF) suspension systems are developed, which are suitable for processing to fabricate polymorphic materials, such as films, fibers, and coatings. The obtained graphene/SF nanocomposites maintain the electronic advantages of graphene, and they also allow tailorable mechanical performance to form including ultrahigh stretchable (with a strain to failure to 611 ± 85%), or high strength (339 MPa) and high stiffness (7.4 GPa) material systems. More remarkably, the electrical resistances of these graphene/SF materials are sensitive to material deformation, body movement, as well as humidity and chemical environmental changes. These unique features promise their utility as wearable sensors, smart textiles, intelligent skins, and human–machine interfaces.     

Graphene‐Directed Supramolecular Assembly of Multifunctional Polymer Hydrogel Membranes

Polymer‐based nanoporous hydrogel membranes hold great potential for a range of applications including molecular filtration/separation, controlled drug release, and as sensors and actuators. However, to be of practical utility, polymer membranes generally need to be fabricated as ultrathin yet mechanically robust, have a large‐area yet be defect‐free and in some cases, their structure needs the capability to adapt to certain stimuli. These stringent and sometimes self‐conflicting requirements make it very challenging to manufacture such bulk nanostructures in a controllable, scalable and cost‐effective manner. Here, a versatile approach to the fabrication of multifunctional polymer‐based hydrogel membranes is demonstrated by a single step involving filtration of an aqueous dispersion containing chemically converted graphene (CCG) and a polymer. With CCG uniquely serving as a membrane‐ and pore‐forming directing agent and as a physical cross‐linker, a range of water soluble polymers can be readily processed into nanoporous hydrogel membranes through supramolecular interactions. With the interconnected CCG network as a robust and porous scaffold, the membrane nanostructure can easily be fine‐tuned to suit different applications simply by controlling the chemistry and concentration of the incorporated polymer. This work provides a simple and versatile platform for the design and fabrication of new adaptive supramolecular membranes for a variety of applications.     

High‐Nanofiller‐Content Graphene Oxide–Polymer Nanocomposites via Vacuum‐Assisted Self‐Assembly

Highly ordered, homogeneous polymer nanocomposites of layered graphene oxide are prepared using a vacuum‐assisted self‐assembly (VASA) technique. In VASA, all components (nanofiller and polymer) are pre‐mixed prior to assembly under a flow, making it compatible with either hydrophilic poly(vinyl alcohol) (PVA) or hydrophobic poly(methyl methacrylate) (PMMA) for the preparation of composites with over 50 wt% filler. This process is complimentary to layer‐by‐layer assembly, where the assembling components are required to interact strongly (e.g., via Coulombic attraction). The nanosheets within the VASA‐assembled composites exhibit a high degree of order with tunable intersheet spacing, depending on the polymer content. Graphene oxide–PVA nanocomposites, prepared from water, exhibit greatly improved modulus values in comparison to films of either pure PVA or pure graphene oxide. Modulus values for graphene oxide–PMMA nanocomposites, prepared from dimethylformamide, are intermediate to those of the pure components. The differences in structure, modulus, and strength can be attributed to the gallery composition, specifically the hydrogen bonding ability of the intercalating species     

Polymer Thin‐Film Transistor Arrays Patterned by Stamping

We present a process to stamp semiconductor polymers suitable for the parallel fabrication of thin‐film transistor island arrays. This process is compatible with roll‐to‐roll fabrication. When a chemically treated elastomeric stamp is pressed against a substrate previously coated with the polymer solution, a capillary force drives the polymer solution into the stamp recesses. Simultaneously, the raised features of the stamp in contact with the substrate absorb the solvent. The resulting polymer thin film reproduces the pattern of the raised features of the stamp. Features with lateral dimensions as small as 2 μm are faithfully reproduced. We use this stamping process to fabricate arrays of polymer thin‐film transistors (TFTs) using poly(fluorene‐co‐bithiophene) and poly(thiophene) semiconductors.