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High-density polyethylene (HDPE) conductive polymer composites are prepared using carbon fillers, such as natural flake graphite (FG), carbon black (CB), and carbon fibre (CF). Here, micro-sized FG as the main conductive filler, nano-sized CB as assistant conductive filler, and short CF as flexibility-enhanced materials are internally mixed with HDPE in a certain weight ratio. Commercial conductive polymer composite is prepared by hot pressing technology. Two kinds of conductive composites are selected by optimising the ratio of carbon fillers and HDPE. CF 4% (CB + FG) 1:5 HDPE 27%  composite has the higher volume conductivity of 20.76 S cm −1  with a bending strength of 39.5 MPa. CF 4% (CB + FG) 1:4 HDPE 30%  composite has the larger bending strength of 53.6 MPa with a volume conductivity of 18.82 S cm −1 . The electrochemical corrosion resistances of those two composite electrodes are investigated over 900 charging/discharging cycles in the lead methanesulfonate flow cell. CF 4% (CB + FG) 1:4 HDPE 30%  composite exhibits better durability than CF 4% (CB + FG) 1:5 HDPE 27%  composite.

Commercial preparation of hybrid carbon filler/HDPE composite electrodes for lead methanesulfonate flow batteries