Properties and potential applications of polymer composites containing secondary fillers

Polymer composites are custom-made materials created by compounding a polymer matrix with various fillers to improve their mechanical, thermal, and electrical properties. The integration of secondary fillers in polymer composites provides fresh possibilities for material improvements and functional diversification. This brief review categorizes some polymer matrices, primary fillers, and secondary fillers utilized in polymer composites. It briefly highlights the impact of secondary fillers on the mechanical, thermal, and electrical properties of the composites. Furthermore, this review summarizes the potential applications of polymer composites containing secondary fillers. Overall, numerous studies indicate that incorporating secondary fillers usually enhances the mechanical, thermal, and electrical properties of polymer composites, irrespective of the type of polymer matrix or primary filler used. These enhancements are due to the bridging effect of secondary fillers, which creates continuous paths for heat and electron flow. Additionally, the formation of conductive networks by secondary fillers improves electrical conduction and stress distribution. The mechanical interlocking of secondary fillers within the matrix increases resistance to mechanical stresses. Moreover, the high thermal and electrical conductivity of secondary fillers improves heat and electron transfer. The synergistic effect with primary fillers also improves load transfer and thermal conductivity. Typical potential applications of thermoset composites containing secondary fillers include thermal management systems, fuel cell technologies, and electronics. Thermoplastic composites containing secondary fillers are potentially applied in packaging, electronics, and fuel cells. Elastomer composites containing secondary fillers are potentially employed in flexible electronics and wearable sensors.

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