The inherent π–π interfacial interaction between carbon nanotubes (CNTs) and polystyrene (PS) makes the CNT/PS composite a representative thermoplastic nanocomposite. However, the strong van der Waals force among CNTs poses challenges to achieving effective dispersion. This review provides an overview of various CNT functionalization methods for CNT/PS composites, encompassing covalent grafting with PS-related polymers and non-covalent modification. A focus in this section involves the pre-introduction surface modification of CNTs with PS or PS-related polymers, substantially enhancing both CNT dispersibility and interfacial compatibility within the PS matrix. Furthermore, a comprehensive summary of the mechanical, electrical, thermal, and electromagnetic shielding properties of CNT/PS nanocomposites is provided, offering an overall understanding of this material. The surface modification methods of CNTs reviewed in this paper can be extended to carbon material/aromatic polymer composites, assisting researchers in customizing the optimal surface modification methods for CNTs, maximizing their dispersibility, and fully unleashing the various properties of CNTs/polymer composites. Additionally, high-performance CNTs/PS composites prepared using appropriate CNT modification methods have potential applications in areas such as electronic devices, sensors, and energy storage and conversion.

To address the challenge of balancing the mechanical, thermal insulation, and flame-retardant properties of building insulation materials, this study presented a facile approach to modify the rigid polyurethane foam composites (RPUFs) via commercial expandable graphite (EG), ammonium polyphosphate (APP), and silica aerogel (SA). The resulting EG/APP/SA/RPUFs exhibited low thermal conductivity close to neat RPUF. However, the compressive strength of the 6EG/2APP/SA/RPUF increased by 49% along with achieving a V-0 flame retardant rating. The residual weight at 700 °C increased from 19.2 wt.% to 30.9 wt.%. Results from cone calorimetry test (CCT) revealed a 9.2% reduction in total heat release (THR) and a 17.5% decrease in total smoke production (TSP). The synergistic flame-retardant mechanism of APP/EG made significant contribution to the excellent flame retardant properties of EG/APP/SA/RPUFs. The addition of SA played a vital role in reducing thermal conductivity and enhancing mechanical performance, effectively compensating for the shortcomings of APP/EG. The cost-effective EG/APP/SA system demonstrates a positive ternary synergistic effect in achieving a balance in RPUFs properties. This study provides a novel strategy aimed at developing affordable building wall insulation material with enhanced safety features.

Polyvinyl chloride (PVC) foam, valued for its mechanical and thermal properties along with cost-effectiveness, is extensively utilized across diverse industries. However, its high volatile organic compound (VOC) emissions hinder its adoption in eco-friendly synthetic leather. This study proposes a solution by optimizing the formulation design and foaming processes and achieving mechanical property enhancement via carbon-fiber-reinforced PVC composite foam (CF/PVC). The aim is to reduce PVC usage via enhancing its intrinsic properties. Systematic investigations were carried out on the impact of foaming raw materials, foaming processes, fiber content, and fiber length on the foaming performance, mechanical properties, and VOC emissions. The material formulation and process parameters were successfully optimized. Further assessment of various indicators such as the density, mechanical properties, and tear resistance of synthetic leather samples confirmed that the innovative CF/PVC foam developed in this study meets the requirements for automotive interior applications. Notably, the tensile strength and tear resistance of CF/PVC composite synthetic leather increased by 50% and 29%, respectively, compared to pure PVC, while VOC emissions decreased by 28%. It is anticipated that a more pronounced reduction in VOC emissions will be achieved in practical automotive interior leather applications when further considering the reinforcing effect of fibers, which leads to a reduction in PVC usage. The findings present a technical reference for innovative applications, aiming to enhance PVC foam performance and minimize emissions.