Dependence of the Polycarbonate Mechanical Performances on Boron Nitride Flakes Morphology

A key requirement for the exploitation of two-dimensional (2D)-crystals in the field of composites relies on their large-scale production. In this respect, liquid phase exfoliation of layered-crystals is emerging as one of the most promising approaches for the scalable production of high-quality 2D-crystals. However, the dependence of the 2D crystal flakes morphology, i.e. thickness and lateral size, on the mechanical properties of the polymer composites is not fully understood yet. Herein, we tackle this issue by designing an environmentally friendly approach, based on the exfoliation of bulk hexagonal-boron nitride (h-BN), widely used as filler in polymer composites for its high intrinsic stiffness, i.e. approaching 1 TPa, in a water/surfactant solution with controlled thickness and lateral size by using cascade ultra-centrifugation. Our approach allows us to obtain two populations of flakes with aspect ratio, i.e. lateral size over thickness, equal to 250 and 350, respectively. The h-BN flakes with tuned aspect ratio are subsequently used as filler in a polycarbonate (PC) matrix by exploiting solution blending in 1,3-dioxolane, a solvent with Hansen’s solubility parameters matching the ones of h-BN, thus enhancing the dispersion of the filler inside the matrix, as evaluated by Raman mapping. We tested the composite mechanical properties finding that flakes with higher aspect ratio show superior reinforcements in terms of both ultimate tensile strength and Young’s modulus, compared with their lower aspect ratio counterparts. As example, at 0.1 wt% of loading, the difference in reinforcement in terms of Young’s Modulus is of 56 MPa, being the increment, compared to pristine PC, of ∼22% for composites produced with higher aspect ratio fillers, whereas it is instead of only ∼17% for lower aspect ratio fillers.