Study on filler content dependence of the onset of positive temperature coefficient (PTC) effect of electrical resistivity for UHMWPE/LDPE/CF composites based on their DC and AC electrical behaviors

Molecular Engineering of Poly(3-Alkylthiophene)s with Enhanced Positive Temperature Coefficient Effects for Intrinsically Safe Lithium-Ion Batteries

The escalating deployment of high-energy density lithium-ion batteries (LIBs) in electric vehicles and energy storage stations has intensified concerns over their thermal safety. Poly(3-alkylthiophene)s (P3ATs), known for their positive temperature coefficient (PTC) effect, are promising candidates for thermally responsive electrodes to suppress LIBs thermal runaway. However, the structure-property relationships governing their PTC behavior remain poorly elucidated. This study systematically synthesizes P3ATs with tailored alkyl side chains and investigates the impact of anion dopants (PF6 -, TFSI-, ClO4 -) on their PTC transition temperatures and resistance ratios. It is revealed that polymers with longer alkyl side chains and smaller dopant anions exhibit lower PTC transition temperatures and higher PTC resistance ratios, attributed to enhanced chain mobility and dopant dissociation efficiency. While the PTC effect demonstrates partial reversibility, increased thermal cycling and extended alkyl side chains accelerate performance degradation due to side-chain entanglement and dopant leaching. Moreover, LiFePO4-based temperature-sensitive electrodes (LFP-P3ATs) effectively shut down the electrode reactions at 110 °C, showing reliable temperature-sensitive characteristics. These findings establish molecular design principles for next-generation smart battery materials with intrinsic thermal protection capabilities.

Flexible Positive Temperature Coefficient Composites (PVAc/EVA/GP-CNF) with Room Temperature Curie Point

Polymeric positive temperature coefficient (PTC) materials with low switching temperature points are crucial for numerous electronic devices, which typically function within the room temperature range (0-40 °C). Ideal polymeric PTC materials for flexible electronic thermal control should possess a room-temperature switching temperature, low room-temperature resistivity, exceptional mechanical flexibility, and adaptive thermal control properties. In this study, a novel PTC material with a room-temperature switching temperature and superb mechanical properties has been designed. A blend of a semi-crystalline polymer EVA with a low melting temperature (Tm) and an amorphous polymer (PVAc) with a low glass transition temperature (Tg) was prepared. Low-cost graphite was chosen as the conductive filler, while CNF was incorporated as a hybrid filler to enhance the material's heating stability. PVAc0.4/EVA0.6/GP-3wt.% CNF exhibited the lowest room temperature resistivity, and its PTC strength (1.1) was comparable to that without CNF addition, with a Curie temperature of 29.4 °C. Room temperature Joule heating tests revealed that PVAc0.4/EVA0.6/GP-3wt.% CNF achieved an equilibrium temperature of approximately 42 °C at 25 V, with a heating power of 3.04 W and a power density of 3.04 W/cm2. The Young's modulus of PVAc0.4/EVA0.6/GP-3wt.% CNF was 9.24 MPa, and the toughness value was 1.68 MJ/m3, indicating that the elasticity and toughness of the composites were enhanced after mixing the fillers, and the mechanical properties of the composites were improved by blending graphite with CNF.

Electrical and Electro-Thermal Characteristics of (Carbon Black-Graphite)/LLDPE Composites with PTC Effect

Electrical properties and electro-thermal behavior were studied in composites with carbon black (CB) or hybrid filler (CB and graphite) and a matrix of linear low-density polyethylene (LLDPE). LLDPE, a (co)polymer with low crystallinity but with high structural regularity, was less studied for Positive Temperature Coefficient (PTC) applications, but it would be of interest due to its higher flexibility as compared to HDPE. Structural characterization by scanning electron microscopy (SEM) confirmed a segregated structure resulted from preparation by solid state powder mixing followed by hot molding. Direct current (DC) conductivity measurements resulted in a percolation threshold of around 8% (w) for CB/LLDPE composites. Increased filler concentrations resulted in increased alternating current (AC) conductivity, electrical permittivity and loss factor. Resistivity-temperature curves indicate the dependence of the temperature at which the maximum of resistivity is reached (Tmax(R)) on the filler concentration, as well as a differentiation in the Tmax(R) from the crystalline transition temperatures determined by DSC. These results suggest that crystallinity is not the only determining factor of the PTC mechanism in this case. This behavior is different from similar high-crystallinity composites, and suggests a specific interaction between the conductive filler and the polymeric matrix. A strong dependence of the PTC effect on filler concentration and an optimal concentration range between 14 and 19% were also found. Graphite has a beneficial effect not only on conductivity, but also on PTC behavior. Temperature vs. time experiments, revealed good temperature self-regulation properties and current and voltage limitation, and irrespective of the applied voltage and composite type, the equilibrium superficial temperature did not exceed 80 °C, while the equilibrium current traversing the sample dropped from 22 mA at 35 V to 5 mA at 150 V, proving the limitation capacities of these materials. The concentration effects revealed in this work could open new perspectives for the compositional control of both the self-limiting and interrupting properties for various low-temperature applications.

Metallic glue for designing composite materials with tailorable properties

Developing materials with tailorable properties has been the long-sought goal of humankind. Forming composite materials with superior properties by combining two or more materials has emerged as a competitive means in the search and design of new materials. However, it is still a grand challenge to use metallic materials as a binder for composites because of their lack of adhesion. In the present work, we proposed a facile and flexible route to synthesize composites using metallic glass as a glue to bond various materials, ranging from conductors to insulators, and metals to nonmetals, together. The mechanical, magnetic and electrical performances of the composites can be manually regulated by changing the addition ratios of the metallic glass glue and the corresponding admixture. In addition, porous structures were also obtained and tuned by dissolving the soluble admixture in water. In principle, our approach provides a new idea for the fabrication and optimization of composites using metallic materials as binders. The outcome of our current research opens up a window not only to synthesize composite materials with tailorable properties universally and flexibly, but also towards the discovery of potential multi-functional metal containing composites.

Electric field-induced alignment of MWCNTs during the processing of PP/MWCNT composites: effects on electrical, dielectric, and rheological properties

High-frequency electric field (HEF) was applied to prepare aligned carbon nanotube (CNT)-reinforced polypropylene (PP) matrix composites during the compression molding process in this article. The effects of the alignment of multiwalled CNTs (MWCNTs) in the PP matrix under HEF on the electrical, dielectric, and rheological properties of the resulting composites were reported. The results showed that the composites prepared in the presence of the electric field had better conductivity than those of the untreated composites. The dielectric property measurement indicates that MWCNTs aligning along the direction of the imposed electric field greatly improved the dielectric properties of composites. Rheological analysis showed that the storage modulus of the aligning direction samples is higher than the value of the untreated composites and the microstructure of the composite has been changed due to the effect of HEF.

Distinct positive temperature coefficient effect of polymer-carbon fiber composites evaluated in terms of polymer absorption on fiber surface

In this article, the positive temperature coefficient (PTC) effect was studied for high-density polyethylene (HDPE)/carbon fiber (CF) composites. All of the samples showed a significant PTC effect during the heating processes without a negative temperature coefficient (NTC) effect, even at a temperature much higher than the melting point of the polymer matrix. An ever-increasing PTC intensity with increasing thermal cycles was observed in our study that had never been reported in previous research. The absence of a NTC effect resulted from the increased binding force between the matrix and fillers that contributed to the very special structure of CF surface. We incorporated thermal expansion theory and quantum tunneling effects to explain PTC effect. From the SEM micrographs for the HDPE/CF composites before and after the different thermal cycles, we found that the surface of CF was covered with a layer of polymer which resulted in a change in the gap length between CF and HDPE and its distribution. We believed that the gap change induced by polymer absorption on the fiber surface had a great effect on the PTC effect.

Considerable different frequency dependence of dynamic tensile modulus between self-heating (Joule heat) and external heating for polymer--nickel-coated carbon fiber composites

Dynamic tensile moduli of polyethylene--nickel-coated carbon fiber (NiCF) composites with 10 and 4 vol % NiCF contents under electrical field were measured by a homemade instrument in the frequency range of 100--0.01 Hz. The drastic descent of the storage modulus of the composite with 10 vol % was verified in lower frequency range with elevating surface temperature (T(s)) by self-heating (Joule heat). The composite was cut when T(s) was beyond 108 °C. On the other hand, the measurement of the composite with 4 vol % beyond 88 °C was impossible, since T(s) did not elevate because of the disruption of current networks. Incidentally, the dynamic tensile moduli by external heating could be measured up to 130 and 115 °C for 10 and 4 vol %, respectively, but the two composites could be elongated beyond the above temperatures. Such different properties were analyzed in terms of crystal dispersions, electrical treeing, and thermal fluctuation-induced tunneling effect.