In situ exfoliation method to fabricate a graphene-reinforced polymer matrix composite

A graphene-reinforced polymer matrix composite, comprising a distribution of graphite microparticles and mechanically exfoliated single-or multi-layer graphene nanoparticles in a thermoplastic polymer matrix, wherein the composite comprises contamination-free graphene-polymer interfaces, wherein the polymer adheres to or is covalently bonded to the graphene-polymer interfaces,

• wherein the single-or multi-layer graphene nanoparticles are directionally aligned, thereby providing one-, two- or three-dimensional reinforcement of the polymer matrix phase, and
• wherein between about 50% to about 90% by weight of the graphite microparticles and the single-or multi-layer graphene nanoparticles are the single-or multi-layer graphene nanoparticles.