Al₂O₃ Dispersion-Induced Micropapillae in an Epoxy Composite Coating and Implications in Thermal Conductivity

Al₂O₃ particles with different sizes were dispersed into an epoxy precursor to improve the thermal conductivity (TC) of the epoxy coating. Al₂O₃ particles tend to aggregate in epoxy, and the aggregation becomes more apparent (formation of micropapillae when the particle size is larger than 1 μm) with the increase of particle size. The calculated fast aggregation rates of various-size Al₂O₃ particles in epoxy showed that the fast aggregation rate increased to a maximum rate of 6.37 × 10^-20 m³·s^-1 at a particle size of 200 nm and then decreased to a plateau value with the increase of particle size. The high fast aggregation rate caused the aggregation and the formation of nano- and micropapillae, causing the heterogeneous distribution of Al₂O₃ particles. These micropapillae were separated by epoxy, which made formation of continuous pathways fail, causing the reduction of TC and heterogeneous heat distribution. The highest thermal conductivity of 2.52 W/m·K and uniform heat distribution were observed at the optimum filler size of 30 nm. The research findings provide the knowledge of optimizing particle size on constructing a thermally conductive polymer composite.