Functionally tuned nanolayered graphene as reinforcement of polyethylene nanocomposites for lightweight transportation industry

System integration and multifunctionality requirements of high-performance materials in the transportation sector are pushing manufacturers to search for advanced functional polymers that are easy to recycle, cost-effective and not energy intensive. This study reports, for the first time, an advanced and lightweight functional nanocomposite material with higher thermal deformation resistance and thermo-mechanical properties than those of conventional polyolefins used in the aforesaid sector. This unique material consists of a biphasic polyolefin system, with Polyethylene (PE) being the macro phase and Polypropylene (PP) being the micro phase, and a novel surface-active nanostructured functional graphene, which thermodynamically co-locate itself at the interface of the PE/PP binary system, thanks to our proposed strategic mixing mechanism. It is proven that the targeted interfacial localization of the novel functional nanolayered graphene promoted a nucleation-controlled PE crystallization, as demonstrated by optical microscopy and studies on macro phase non-isothermal crystallization kinetics. This justifies the remarkable enhancement of nanocomposite’s thermo-mechanical properties, leading to the potential use of this new functional material as a lightweight thermoplastic olefinic nanocomposite in the above-mentioned industrial sector. Lastly, the outcome of this study opens new avenues in the applications of advanced, lightweight, and functional polyolefin-based materials for diverse applications, increasing the environmental footprint.