Fabrication
of high-performance thermally conductive polymer nanocomposites
through melt processing is crucial for large-scale industrial applications.
However, this remains underdeveloped due to challenges with regulating
nanofillers in viscous polymer melts. Herein, we propose a high-speed
melt stretching strategy to prepare thermally conductive nanocomposite
films of high-density polyethylene/boron nitride (PE/BN). By rapidly
applying a maximum 80× stretch ratio to the high-temperature
composite melt using a homemade two-drum extensional machine, two-dimensional
BN nanosheets are highly oriented and redispersed within the PE matrix.
This enables the production of nanocomposite films with superstrong
mechanical properties, including high strength (>90 MPa) and modulus
(>3 GPa). The horizontally aligned BN nanosheets simultaneously
create
fast pathways for phonon transport, resulting in a high in-plane thermal
conductivity of 6.56 W/m K for the film with 40 wt % BN. This value
is superior to previous reports on polymer/BN composites with similar
filler fractions and ensures an excellent cooling capability of the
film for commercial LED modules. Additionally, the melt-stretched
PE/BN films demonstrate significantly improved thermo-mechanical and
electrical insulating properties compared to their hot-pressed counterparts,
attributed to the microstructural advantages. This work offers a viable
melt processing approach for developing high-performance general plastic-based
thermally conductive films toward electronic device applications.