Two-Phase-Interfaced, Graded-Permittivity Titania Electrical Insulation by Atmospheric Pressure Plasmas

Improving Charge Storage of Biaxially-Oriented Polypropylene under Extreme Electric Fields by Excimer UV Irradiation

Biaxially-oriented polypropylene (BOPP) is one of the most commonly used materials for film-based capacitors for power electronics and pulsed power systems. To address the pressing issue of performance-limiting loss under extreme electric-fields, here a one-step, high-throughput, and environment-friendly process based on very low-dose ultra-violet irradiation from KrCl (222 nm) and Xe2 (172 nm) excimer is demonstrated. The performance of commercial BOPP is boosted in terms of withstanding electric-field extremes (Weibull breakdown strength 694 to 811 V µm-1 by 17% at 25 °C and 428 to 651 V µm-1 by 52% at 120 °C), discharged energy density, and conduction losses. Importantly, the depth profile of space charge is precisely measured in situ with a high resolution of 500 nm by laser induced pressure pulse. Consequently, the space charge effect and electric-field distortion are reduced and related to the improved polymer films. It is demonstrated that energetic UV photons act as scissors for BOPP chains and dissociate oxygen molecules leading to the more thermally stable oxygen-containing structures, as deep traps to impede charge migration. This work provides a promising approach to produce polymers with customized microscopic characteristics that is compatible with the assembly lines of polymer-based capacitors.

Superior Surface-Insulated Polymers with Low Leakage Current Enabled by Tailored Coatings Deposited with Colliding Plasma Jets

Insufficient surface insulation margin is the primary challenge for a 10 kV plus high-voltage semiconductor module. Surface charge accumulation and electric field distortion are the leading causes of surface insulation failure. Power modules restrict leakage loss, so only insulation dielectrics with low surface conductivity can be used. However, low conductivity, accumulated charge dissipation, and distorted electric field optimization have always been contradictory. A potential barrier increase and electron affinity decrease are both less coupled approaches with conductivity, which may have the potential for reducing surface charge accumulation. Here, surface charge accumulation inhibition and local electric field optimization were synchronously realized by tailored coating deposition with colliding plasma jets. This novelty approach leads to a finer interfacial modification of the triple junction and its nearby interfaces. The high-barrier and low-affinity coatings deposited by colliding plasma jets suppress charge injection (electrode-polymer interface) and promote charge dissipation (gas-polymer interface), respectively. At the same time, the small-area semiconductor deposited at the triple junction relieves the distortion of the electric field. In the end, while maintaining a low leakage current, the surface flashover voltages of polytetrafluoroethylene, polyimide, and epoxy packaging polymers are significantly increased by 69.7, 43.2, and 39.6%, respectively. Notably, the normalized leakage loss is less than 3/10,000 of the commercially available SiC module, which vastly differs from the surface insulation improvement strategy that blindly increases surface conductivity. This tailored coating modification strategy provides a new idea for dielectric research. It has reasonable practicability due to fast, cheap, and environmentally friendly colliding plasma jets.

Largely Enhanced Surface Flashover Voltage of Poly(ether Imide) by Scalable and Durable ZnO Coating: A Gift from In Situ Growth

Dielectric materials with high surface electric insulation strength are in great demand in a high-power space solar cell array (SSCA). A moderately conductive surface is favorable to inhibit charge accumulation and mitigate electric field distortion, thus improving the surface flashover voltage. Although numerous modification methods have been proposed to achieve this goal, the facile, efficient, scalable, and environmentally friendly modification strategy remains a critical challenge to date. Considering the excellent charge modulation ability of ZnO and its mild preparation conditions, a facile and economical hydrothermal strategy was proposed to fabricate in situ a durable poly(ether imide)/zinc oxide (PEI/ZnO) coating with a high charge decay rate. The blooming flower-like ZnO in the coating is proved to play a key role in enhancing lateral charge dissipation on the surface of PEI, thereby suppressing surface charge accumulation. It was also shown that the shielding effect of ZnO on high-energy photons during flashover and the catalytic effect of Zn2+ on PEI molecular chains during hydrothermal treatment had a facilitating and suppressing effect on outgassing, respectively, and consequently affected the flashover. Excitingly, the synergistic effects of both accelerated charge dissipation and suppressed outgassing helped to improve the flashover voltage of PEI by up to 36.7%. The strategy selected here is efficient, scalable, and facile, and the coating is durable, which makes sense for commercial promotion.

Tailoring Organic/Inorganic Interface Trap States of Metal Oxide/Polyimide toward Improved Vacuum Surface Insulation

High-voltage and high-power devices are indispensable in spacecraft for outer space explorations, whose operations require aerospace materials with adequate vacuum surface insulation performance. Despite persistent attempts to fabricate such materials, current efforts are restricted to trial-and-error methods and a universal design guideline is missing. The present work proposes to improve the vacuum surface insulation by tailoring the surface trap state density and energy level of the metal oxides with varied bandgaps, using coating on a polyimide (PI) substrate, aiming for a more systematical workflow for the insulation material design. First-principle calculations and trap diagnostics are employed to evaluate the material properties and reveal the interplay between trap states and the flashover threshold, supported by dedicated analyses of the flashover voltage, secondary electron emission (SEE) from insulators, and surface charging behaviors. Experimental results suggest that the coated PI (i.e., CuO@PI, SrO@PI, MgO@PI, and Al2O3@PI) can effectively increase the trap density and alter the trap energy levels. Elevated trap density is demonstrated to always yield lower SEE. In addition, increasing shallow trap density accelerates surface charge dissipation, which is favorable for improving surface insulation. CuO@PI exhibits the most remarkable increase in shallow trap density, and accordingly, the highest flashover voltage is 42.5% higher than that of pristine PI. This study reveals the critical role played by surface trap states in flashover mitigation and offers a novel strategy to optimize the surface insulation of materials.

High Performance Epoxy Composites Containing Nanofiller Modified by Plasma Bubbles

The thermal conductivity of polymer materials is a fundamental parameter in the field of high-voltage electrical insulation. When the operating frequency and power for electrical equipment or electronic devices increase significantly, the internal heat will increase dramatically, and the accumulation of heat will further lead to insulation failure and serious damage of the whole system. The addition of filler with high thermal conductivity into polymer is a common solution. However, the interfacial thermal resistance between filler and bulk materials is the major obstacle to improve thermal conductivity. Herein, in order to reduce the interfacial thermal resistance, nanofillers are modified by plasma technology. The surface modification of nano-Al₂O₃ is carried out using plasma bubbles with three atmospheres (Ar, Ar+O₂, air) as well as coupling agent. The situation of surface grafting before and after the modification is characterized using FTIR, XPS, and SEM. The effect of the mechanism of modification on the thermal conductivity and reaction pathway is investigated. The results showed that the thermal conductivity after plasma modification is increased significantly. Especially, the thermal conductivity is increased by 35% for the sample modified by Ar+O₂ atmosphere. This results because more hydroxyl is introduced on the filler surface by the plasma bubbles, which enhance the interface compatibility between filler and epoxy. In addition, surface insulation performance for the modified samples also is enhanced by 14%. This is associated with the change of surface resistance and trap distribution. These results provide potential support for the development of fabrication for high performance epoxy composites.

Rapid Evaluation of Material Surface Modification by a Dielectric Barrier Discharge Based on Fluorescence Coloring and Image Processing Technologies

In recent years, improving the surface properties of large-scale insulation by plasma modification has attracted extensive attention with the development of power systems and high-tech industries. However, routine evaluations of the modification effect and uniformity require complicated tests after the plasma is powered off, which waste a lot of time and cannot regulate the modification effect online. In this study, a novel fluorescence-assisted dielectric barrier discharge (DBD) for fabricating a functional film is developed, and a rapid evaluation method of the modification effect and uniformity is proposed based on fluorescence coloring and image processing technologies. The results show that the addition of an organic fluorescent agent in the DBD with hexamethyldisiloxane (HMDSO) has no negative effect on the plasma discharge and modification effect, and the fluorescence-assisted DBD successfully fabricates the functional films with typical chromogenic groups (N-H and S═O) that exhibit typical fluorescence under an UV lamp. According to image processing and parameter extraction, the plasma-assisted fluorescent film is converted into a two-dimensional (2D) color map with nine color levels, and three characteristic parameters are proposed to evaluate the modification effect rapidly and directly. It shows that the warmer the color of the treated sample, the better the hydrophobicity and electrical insulating properties, where the red region represents the optimally modified surface, while the blue region represents the worst one. The area, shape, and integrity of the plasma modification are clarified quantificationally, which provides the possibility of further online evaluation of the modification effect and uniformity by the plasma treatment.

Different Radial Modification Profiles Observed on APPJ-Treated Polypropylene Surfaces according to the Distance between Plasma Outlet and Target

The plasma jet transfer technique relies on a conductive wire at floating potential, which, upon entering in contact with a primary discharge, is capable of igniting a small plasma plume at the distal end of a long flexible plastic tube. In this work, two different long tube configurations were employed for the surface modification of polypropylene (PP) samples using argon as the working gas. One of the jet configurations has a thin copper (Cu) wire, which was installed inside the long tube. In the other configuration, the floating electrode is a metallic mesh placed between two plastic tubes in a coaxial arrangement. In the first case, the tip of the Cu wire is in direct contact with the working gas at the plasma outlet, whereas, in the second, the inner plastic tube provides an additional dielectric barrier that prevents the conductor from being in contact with the gas. Water contact angle (WCA) measurements on treated PP samples revealed that different surface modification radial profiles are formed when the distance (d) between the plasma outlet and target is changed. Moreover, it was found that the highest WCA reduction does not always occur at the point where the plasma impinges the surface of the material, especially when the d value is small. Through X-ray photoelectron spectroscopy (XPS) analysis, it was confirmed that the WCA values are directly linked to the oxygen-functional groups formed on the PP surfaces after the plasma treatment. An analysis of the WCA measurements along the surface, as well as their temporal evolution, together with the XPS data, suggest that, when the treatment is performed at small d values, the plasma jet removes some functional groups at the point where the plasma hits the surface, thus leading to peculiar WCA profiles.