Abstract

This study introduces an efficient and scalable method for the top-down exfoliation of graphite into graphite nanoplatelets (GNPs) using polyketones (PKs) functionalized with Diels–Alder (DA) active groups. Leveraging the reversible covalent interactions facilitated by furan and thiophene moieties in PK, combined with melt-mixing and shear force, this process achieves significant exfoliation while preserving the structural integrity of the resulting material. Thermal and rheological analyses demonstrate enhanced interfacial adhesion and stability within polymer composites attributed to the DA-driven interactions between functionalized PK and graphite. Comparative evaluations demonstrate that furan-functionalized PK exhibits superior exfoliation efficiency, highlighting its potential for producing high-quality exfoliated graphite suitable for advanced nanocomposite applications that require enhanced thermal, mechanical, and electrical properties. This method seamlessly integrates sustainability with industrial scalability, offering significant advancements in developing GNP-based materials.