Insight into the interface effect and PTC effect on the temperature-adaptive electrical conductivity of epoxy composite

Doping functional fillers into the polymeric matrix is an effective strategy to improve the electrical, thermal, and other performance of insulating materials. It is imperative to understand the influence of fillers on the charge carrier behavior to achieve better regulation effectiveness. In this work, micrometer-sized and nano-sized ceramic particles with positive temperature coefficient (PTC) electrical resistivity are employed to prepare the epoxy composites, whose electrical conductivity under different temperature and electric field, space charge characteristics, permittivity, and electric field distribution are studied. It is found that the doping of a PTC filler shifts the electrical conduction from bulk-controlled to electrode-limited, determining the quantity of charge carriers within epoxy composites. While the interface effect mainly affects the transport process of charge carriers, it would fail to dominate the electrical conduction since the abundant charge carrier introduced by the semiconductive functional filler. Combined with the reinforced interface effect, the electrical conductivity–temperature characteristic of the epoxy nanocomposite is optimized, leading to the reduction in the maximum electric field within electrical equipment insulation by 55%. These findings emphasize the synergistic regulation of charge carrier amount and transport, which contributes to the precision design of polymeric composites doped with functional fillers.