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ABSTRACT:The influence of Joule heating treatments and carbon black (CB) on the electrical and thermal behavior of epoxy resin composites is well described in this article. The effect of CB and Joule heating on network structure characteristics, such as shrinkability, interparticle distance between conductive particles, crosslinking density, hardness, thermoelectric power, thermal conductivity, the thermal expansion coefficient, and scanning electron microscopy, of epoxy composites was investigated. The electrical conductivity () of epoxy resin correlated with the volume fraction of CB and Joule heating treatment. increased continuously with increasing CB content, and Joule heating increased the level of , which makes it attractive for electronic utilization. The for fresh and Joule heating samples was recorded during heating-cooling cycles. The conduction mechanism of for epoxy composites was identified. The activation energy and hopping energy for two batches of epoxy as a function of CB content were estimated. The hopping distance, the state density at the Fermi level, and the radius of localized wave function versus CB content were evaluated. The current-voltage-temperature characteristics of fresh and Joule heating samples of epoxy composites were demonstrated. The thermal reliability was tested by means of temperature-time characteristics when certain applied power was on and off for several cycles. The specific heat and amount of heat transfer by radiation and convection were calculated based on the energy balance model for two batches. The results indicate that the Joule heating effect is a very effective and prospective way of enhancing the electrical and thermal stability of epoxy-CB composites for consumer use as heaters and in other electronic areas such as electromagnetic shielding effectiveness.

This paper shows the wide application range (such as electrical self‐heating and electromagnetic shielding effectiveness) of composites consisting of conductive carbon black/aluminum flakes (CBA) filler and epoxy insulative matrix. The effect of CBA content on the network structure of epoxy matrix was investigated in detail. Static electrical conductivity increases linearly with the increase of filler concentration at the interface in epoxy composites. The large decrease of the conductivity as a function of the temperature is analyzed in terms of the negative temperature coefficient of conductivity (NTCC) effect. The influence of viscosity, surface energy and barrier highest energy on the NTCC behaviour in the composite is also considered. Based on these results, a new interpretation is proposed to explain the NTCC phenomena by computing the swelling force among conductive phases. The correlations of conductivity during the temperature cycling and activation energy were analyzed. The effects of dynamic ageing at various temperatures on the resistivity are reported. Current–voltage–temperature characteristics for epoxy with different contents of CBA were examined in detail. A model based on the law of energy conservation is proposed to calculate the specific heat and amount of heat dissipation. The static charge of the epoxy–CBA composites was estimated. The correlation between electromagnetic wave‐shielding effectiveness (EMS), conductivity and frequency of epoxy composites with different filler contents is also discussed. Furthermore, the effect of annealing on EMS of epoxy composites was examined. © 2002 Society of Chemical Industry

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