An efficient interface model to develop scalable methodology of melt processing of polypropylene with graphene oxide produced by an improved and eco‐friendly electrochemical exfoliation

This study developed a scalable and straightforward adaptation methodology for melt processing of polypropylene (PP) to provide a high degree of exfoliation of multilayer graphene oxide (GO) by using a high‐shear mixer. GO was first produced by an improved and eco‐friendly electrochemical exfoliation by using an environmentally friendly aqueous methanesulfonic acid (MSA) and a sodium sulfate salt system to minimize the environmental impact. The produced GOs then were melt blended with PP and their mechanical, thermal, and morphological properties were investigated under different GO loadings to attain ideal configuration and increase interfacial interactions between polymer matrix and reinforcer. Comparisons were made by producing different PP composites using two different GO types produced in salt and acid environments. Additionally, by applying different voltages to salt system, the effect of applied voltage on the properties of both GO material and the composites were discussed. The characterization results indicated that GO obtained in MSA solution caused a 71% increase in flexural modulus and 46% in flexural strength with the addition of 1 wt% GO. The rheological characterization also showed that dispersion and viscosity improved with lower GO loadings compared to neat polymer by providing cost‐effective and scalable graphene manufacturing.