The aims of this study were to fabricate lightweight composites having isotropic electrical and thermal conductivities. The composites consist of expanded polypropylene (EPP) and chopped carbon fibers. They were randomly mixed together and fusion-bonded using steam at a high temperature with a high saturation vapor pressure. The quasi-isotropic electrical conductivities and isotropic thermal conductivities of the composites were achieved by the secondary expansion of the EPP. The densities, electrical and thermal conductivities of the composites with volume fractions of carbon fibers ranging from 4.2 to 8.5% were in the ranges of 0.2-0.3 g/cm 3 , 1.1-105.8 × 10 −4 S/cm, and 0.51-0.86 W/mK, respectively. The thermal conductivities of the composites were shown to increase monotonically with increasing volume fractions of carbon fibers, which is in agreement with the theoretical values using the series model.
IntroductionLightweight and multifunctional materials are of interest in many industrial fields. [1][2][3][4][5][6][7] Electrical and thermal conductivities can be useful for applications such as the heat sink or electromagnetic wave shielding. Multifunctional materials can be made by mixing two or more materials, or by structural inducement.[1,6-14] To obtain isotropic properties, powder type fillers, for example, carbon black, carbon nanotube, and graphene have been used. The fillers of powder form are easy to realize isotropic properties. However, using fillers has a disadvantage which is the difficulty in filler dispersion in the matrix. Rod-shape fillers may result in better electrical and thermal conductivities than the powder-type fillers. However, it may result in anisotropic properties after the process because the rod-shaped filler with a high aspect ratio will inevitably have orientation depending on the direction of the mold flow or orientation biased towards the in-plane direction due to the shape of the filler even in the absence of mold flow. Consequently, electrical or thermal conductivities of the composite between the in-plane and the out-of-plane directions may become quite different. [10][11][12][13][14][15] In order to enhance the conductivities in the out-of-plane direction and thus to realize isotropic conductivities, expanded polypropylene (EPP) and carbon fibers were used in this study.