This work demonstrates how the addition of few-layer graphene (FLG) influences the processability and mechanical properties of the mixed polyolefin waste stream (R-(PE/PP)). Three different types of compounds were investigated: (1) R-(PE/PP) with FLG; (2) blends of R-(PE/PP) with prime polyethylene (PE) or polypropylene (PP) or PP copolymer; and (3) R-(PE/PP) with both the prime polymer and FLG. The processability was assessed by measuring the torque during melt extrusion, the melt flow index (MFI), and viscosity of the compounds. Investigations of the processability and mechanical properties of the composites indicate that the presence of FLG can reinforce the composites without hindering the processability, an unusual but desired feature of rigid fillers. A maximum increase in tensile strength by 9%, flexural strength by 23%, but a reduction in impact strength were observed for the compounds containing R-(PE/PP), 4 wt.% FLG, and 9 wt.% prime PP. The addition of FLG concentrations higher than 4 wt.% in R-(PE/PP), however, resulted in higher tensile and flexural properties while preserving the impact strength. Remarkably, the addition of 10 wt.% FLG increased the impact strength of the composite by 9%. This increase in impact strength is attributed to the dominant resistance of the rigid FLG particles to crack propagation.

This work investigated the photostabilizing role of a commercially available few-layer graphene (FLG) in mixed polyolefins waste stream (MPWS), ensuring extended lifespan for outdoor applications. The investigation was conducted by analyzing carbonyl content increase, surface appearance, and the retention of mechanical properties of UV-exposed MPWS/FLG composites. Despite the likely predegraded condition of MPWS, approximately 60%, 70%, 80%, and 90% of the original ductility was retained in composites containing 1, 4, 7, and 10 wt.% FLG, respectively. Conversely, just 20% of the original ductility was retained in unfilled MPWS. Additionally, less crack density and lower carbonyl concentrations of the composites also highlighted the photoprotection effect of FLG. For prime polyolefin blends, only 0.5 wt.% or 1 wt.% FLG was sufficient to preserve the original surface finishing and protect the mechanical properties from photodegradation. Hence, it was observed that MPWS requires more FLG than prime polyolefin blends to get to comparable property retention. This could be attributed to the poor dispersion of FLG in MPWS and inevitable uncertainties such as the presence of impurities, pre-degradation, and polydispersity associated with MPWS. This study outlines a potential approach to revalorize MPWS that possess a minimal intrinsic value and would otherwise be destined for landfill disposal.

This work demonstrates the potentials of a commercially available few-layer graphene (FLG) in enhancing the electro-dissipative properties, mechanical strength, and UV protection of polyolefin blend composites; interesting features of electronic packaging materials. Polyethylene (PE)/ polypropylene (PP)/ FLG blend composites were prepared following two steps. Firstly, different concentrations of FLG were mixed with either the PE or PP phases. Subsequently, in the second step, this pre-mixture was melt-blended with the other phase of the blend. FLG-filled composites were characterized in terms of electrical conductivity, morphological evolution upon shear-induced deformation, mechanical properties, and UV stability of polyolefin blend composites. Premixing of FLG with the PP phase has been observed to be a better mixing strategy to attain higher electrical conductivity in PE/PP/FLG blend composite. This observation is attributed to the influential effect of FLG migration from a thermodynamically less favourable PP phase to a favourable PE phase via the PE/PP interface. Interestingly, the addition of 4 wt.% (~2 vol.%) and 5 wt.% (~2.5 vol.%) of FLG increased an electrical conductivity of ~10 orders of magnitude in PE/PP—60/40 (1.87 × 10⁻⁵ S/cm) and PE/PP—20/80 (1.25 × 10⁻⁵ S/cm) blends, respectively. Furthermore, shear-induced deformation did not alter the electrical conductivity of the FLG-filled composite, indicating that the conductive FLG network within the composite is resilient to such deformation. In addition, 1 wt.% FLG was observed to be sufficient to retain the original mechanical properties in UV-exposed polyolefin composites. FLG exhibited pronounced UV stabilizing effects, particularly in PE-rich blends, mitigating surface cracking and preserving ductility.