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Functional Polymer Composite with Core-Shell Ceramic Filler: II. Rheology, Thermal, Mechanical, and Dielectric

Andrzej Rybak1

  • 1ABB Corporate Technology Center, Starowislna 13A, 31-038 Krakow, Poland.

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This study introduces core-shell ceramic particles (alumina coated by aluminum nitride) to improve epoxy resin electrical insulation. The enhanced composite shows better thermal conductivity and mechanical strength while maintaining crucial electrical properties.

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core-shell fillerdielectric propertieselectrical insulationepoxy-matrix compositemultifunctional compositesthermal conductivity

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Area of Science:

  • Materials Science
  • Electrical Engineering
  • Polymer Science

Background:

  • Epoxy resin composites are vital electrical insulators in electrification devices.
  • Optimizing thermal, mechanical, and dielectric properties is crucial for their functionality.
  • A novel core-shell filler (alumina@aluminum nitride) was previously developed to enhance thermal conductivity.

Purpose of the Study:

  • To comprehensively evaluate the performance of epoxy composites filled with core-shell Al2O3@AlN particles.
  • To assess if electrical insulation properties are maintained with enhanced thermal conductivity.
  • To compare the core-shell filled composite with a reference system using standard fillers.

Main Methods:

  • Rheological analysis
  • Tensile strength testing
  • Dynamic mechanical analysis
  • Dilatometry
  • Dielectric permittivity, strength, and electrical resistivity measurements

Main Results:

  • Core-shell filler integration did not hinder processability (rheology).
  • Mechanical properties (tensile strength, DMA) improved compared to the reference.
  • Lower coefficient of linear thermal expansion observed, potentially improving adhesion.
  • Dielectric strength increased by 16% without compromising insulation.
  • Significant enhancement in thermal conductivity (63% relative increase) was confirmed.

Conclusions:

  • The epoxy composite with core-shell Al2O3@AlN particles offers enhanced thermal conductivity.
  • Key electrical insulation properties are maintained or improved.
  • This material is suitable for electrical insulation applications requiring superior thermal performance.