At present, the rapid accumulation of heat and the heat dissipation of electronic equipment and related components are important reasons that restrict the miniaturization, high integration, and high power of electronic equipment. It seriously affects the performance and life of electronic devices. Hence, improving the thermal conductivity of polymer composites (TCPCs) is the key to solving this problem. Compared with manufacturing intrinsic thermally conductive polymer composites, the method of filling the polymer matrix with thermally conductive fillers can better-enhance the thermal conductivity (λ) of the composites. This review starts from the thermal conduction mechanism and describes the factors affecting the λ of polymer composites, including filler type, filler morphology and distribution, and the functional surface treatment of fillers. Next, we introduce the preparation methods of filled thermally conductive polymer composites with different filler types. In addition, some commonly used thermal-conductivity theoretical models have been introduced to better-analyze the thermophysical properties of polymer composites. We discuss the simulation of λ and the thermal conduction process of polymer composites based on molecular dynamics and finite element analysis methods. Meanwhile, we briefly introduce the application of polymer composites in thermal management. Finally, we outline the challenges and prospects of TCPCs.

Electrically conductive polymer composites are in high demand for modern technologies, however, the intrinsic brittleness of conducting conjugated polymers and the moderate electrical conductivity of engineering polymer/carbon composites have highly constrained their applications. In this work, super high electrical conductive polymer composites were produced by a novel hot embossing design. The polydimethylsiloxane (PDMS) composites containing short carbon fiber (SCF) exhibited an electrical percolation threshold at 0.45 wt % and reached a saturated electrical conductivity of 49 S/m at 8 wt % of SCF. When reducing the sample thickness from 1.0 to 0.1 mm by the hot embossing process, a compression-induced percolation threshold occurred at 0.3 wt %, while the electrical conductivity was further enhanced to 378 S/m at 8 wt % SCF. Furthermore, the addition of a second nanofiller of 1 wt %, such as carbon nanotube or conducting carbon black, further increased the electrical conductivity of the PDMS/SCF (8 wt %) composites to 909 S/m and 657 S/m, respectively. The synergy of the densified conducting filler network by the mechanical compression and the hierarchical micro-/nano-scale filler approach has realized super high electrically conductive, yet mechanically flexible, polymer composites for modern flexible electronics applications.

A new wave energy flow (WEF) map concept was proposed in this work. Based on it, an improved technique incorporating the laser scanning method and Betti’s reciprocal theorem was developed to evaluate the shape and size of damage as well as to realize visualization of wave propagation. In this technique, a simple signal processing algorithm was proposed to construct the WEF map when waves propagate through an inspection region, and multiple lead zirconate titanate (PZT) sensors were employed to improve inspection reliability. Various damages in aluminum and carbon fiber reinforced plastic laminated plates were experimentally and numerically evaluated to validate this technique. The results show that it can effectively evaluate the shape and size of damage from wave field variations around the damage in the WEF map.

A new type of flexible sensor, which could maintain the deformation consistency and achieve the real-time detection of the variation in load of the measured object, was proposed in this work. According to the principle of forced assembly, PDMS was used as the substrate of sensitive components and electrodes, while carbon fiber was added as a conductive medium to prepare a polymer-based flexible sensor, which effectively overcame the deformation limitation and output instability of conventional flexible sensors due to different substrates of sensitive components and the electrode. Combined with the sensor structure and the forced assembly method, a theoretical analysis of its conductive measurement mechanism was carried out. Meanwhile, an experimental test device was designed to test and analyze the output characteristics of the flexible sensor under a static and dynamic alternating load. The results show that the flexible sensor exhibited linear output under the dynamic alternating load of 10 kN to 60 kN and frequency of 3 Hz. Peak and valley value had the same phase with the load extremes. The dynamic and static experiments show that the resistance output signal and the sensitivity was in the range of 310~624.15 Ω and 171–183 N/Ω respectively. However, due to the hysteresis of the elastic recovery of the polymer, the output repeatability of the flexible sensor under the dynamic alternating load was 5.03% and 0.78% lower than that of the static load, respectively. Combined with the static and dynamic experiments, it was verified that the polymer-based flexible sensor can maintain the same deformation characteristics with the measured object, and at the same time outputted a resistance signal with a certain mapping relationship with the applied load. The repeatability of the output signal under dynamic and static experiments was within ±7%, which can meet the measurement requirements of the fatigue life of the measured body during periodic load.

A highly sensitive and flexible piezoresistive sensor is fabricated by Spacial Confined Forced Network Assembly (SCFNA) method in this paper. Polydimethylsiloxane (PDMS)/ short carbon fiber (SCF)/ carbon nanotube (CNT) composite with a V-shaped groove microstructure on surface is prepared as the flexible sensitive components. Because the size of SCF is larger than the microstructure mold, SCF is hard to enter the microstructure. So a double-layer conductive network is constructed by spacial confined assembly of microstructure mold, so that pure CNT network is in the layer of microstructure and the SCF/CNT network is in the layer of non-microstructure. As SCF is more effective in enhancing the conductivity of PDMS than CNT due to its larger aspect ratio and more compact network, the conductivity of SCF/CNT network is higher than CNT network. But the stability and sensitivity of CNT network is higher than SCF/CNT network because the smaller size and more homogeneous dispersion of CNT. Therefore the laminating of SCF/CNT network and CNT network with microstructure on surface could have synergistic effect to improve both the conductivity, stability and the sensitivity of sensor. The accuracy rate of the sensing system can reach 91.1%, which provide the relevant basis for the intelligent control of the car seats.

In recent years, superhydrophobic surfaces have attracted significant attention due to their promising applications, especially in ice prevention, reduction in air resistance, and self-cleaning. This study utilizes femtosecond laser processing technology to prepare different surface microstructures on polytetrafluoroethylene (PTFE) surfaces. Through experiments, it investigates the relationship between the solid–liquid contact ratio and surface hydrophobicity. The shape of water droplets on different microstructure surfaces is simulated using ANSYS, and the relationship between surface microstructures and hydrophobicity is explored in the theoretical model. A superhydrophobic surface with a contact angle of up to 166° was obtained by machining grooves with different spacings in polytetrafluoroethylene sheets with femtosecond laser technology. Due to the micro- and nanostructures on the surface, the oleophobicity of the processed oleophilic PTFE surface is enhanced.