Qiyan
Zhang
*a,
Dongmou
Li
a,
Yueqi
Zhong
a,
Yuna
Hu
a,
Shuangwu
Huang
*a,
Shuxiang
Dong
b and
Q. M.
Zhang
*c
aState Key Laboratory of Radio Frequency Heterogeneous Integration, College of Electronics and Information Engineering, Institute of Microelectronics (IME), Shenzhen University, Shenzhen 518060, China. E-mail: zhangqy15@tsinghua.org.cn; mark_huang@szu.edu.cn
bInstitute for Advanced Study, Shenzhen University, Shenzhen, 518061, China
cSchool of Electrical Engineering and Computer Science, Materials Research Institute, The Pennsylvania State University, University Park, PA, USA. E-mail: qxz1@psu.edu
First published on 23rd July 2024
Electrostatic capacitors based on polymer dielectrics are essential components in advanced electronic and electrical power systems. An urgent challenge, however, is how to improve their capacitive performance at high temperatures to meet the rising demand for electricity in a harsh-environment present in the emergent applications such as electric vehicles, renewable energy, and aerospace systems. Here, we report a low-entropy amorphous polymer with locally extended chain conformation comprising high-Tg poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) blended with polystyrene (PS) that exhibits an energy density as high as 5.5 J cm−3 with an efficiency of >90% at an electric field of 600 MV m−1 at 150 °C, outperforming the existing dielectric polymers. Our results reveal that regulating the conformation entropy of polymer chains introduces a favorable locally extended polymer chain conformation, resulting in dense chain packing with short-range ordered but long-range disordered microstructures, and inhibits the transport of electrons in dielectric polymers, consequently, leading to the substantial improvements of capacitive performance at elevated temperatures. This low-entropy approach is scalable, general, ultra-low-cost and simple, paving the way for mass fabrication of high-performance and high-quality polymer films required for high-temperature film capacitors.
Broader contextElectrostatic energy storage capacitors are essential components in modern electrical and electronic systems. Compared to ceramic dielectrics, polymer dielectrics offer higher breakdown strengths, greater reliability, scalability, and lightweight properties, making them ideal for high-voltage applications such as power electronics, power conditioning, and pulsed power. However, current dielectric polymers are limited by relatively low working temperatures, which fail to meet the rising demands of electrical energy storage under the extreme conditions found in electric vehicles, aerospace systems, and power grids. Although high-Tg polymers filled with inorganic nanofillers have shown promising elevated-temperature capacitive performance, the scalability of these nanocomposites remains a significant challenge. They are typically prepared by tedious, complex, and time-consuming methods that are incompatible with the current melt-based processes used for capacitor films. Herein we present a highly scalable dielectric polymer with low-entropy molecular conformations that exhibits superior capacitive performance at elevated temperatures and high applied electric fields. This low-entropy approach is scalable, general, ultra-low-cost, and simple, facilitating the mass production of high-performance and high-quality polymer films required for high-temperature electrostatic energy storage capacitors. |
To address these urgent needs, a variety of high thermal stability engineering polymers15,16 with high glass transition temperature (Tg) such as polyimides (PIs), polycarbonates (PCs) and fluorene polyesters (FPEs), have been exploited as high-temperature dielectric polymers. Unfortunately, although the high-Tg polymers show stable polarization over a broad temperature, all the polymers show poor charge–discharge efficiencies at the applied high electric and thermal fields, which resulted from sharply increased conduction loss attributable to the thermally and electrically assisted charge injection, excitation and transport.4,7 Doping appropriate amounts of wide-bandgap inorganic fillers such as boron nitride nanosheets (BNNS)7 and aluminium oxide (Al2O3)17,18 in high-Tg polymers to form polymer nanocomposites have proved effective in promoting the high-temperature capacitive performance. It is found that the introduced nanofillers are effective in hindering the charge transport to decrease the conduction loss under elevated temperatures and high applied electric fields. It is further observed that the nanofillers can induce the surrounding polymers to form much tighter and more orderly aggregate structures, which restrains the movement of molecular chains and reduces the entropy of local molecular conformations, resulting in the formation of deep-level localized states at the interfacial zones between nanofillers and the polymer matrix and hindering the charge transport in polymer nanocomposites.10,19 These results reveal that the entropy of molecular conformations is a key factor influencing charge transport, which affects the conductivity and energy loss of polymer dielectrics. However, the nanocomposite approaches developed to tune the entropy of polymer molecular conformations at the interface regions introduce complications. High loading of nanofillers in the composites significantly compromises film flexibility, leading to voids and cracks in films. This makes the manufacture of large-scale, low-cost, and uniform polymer films challenging.1,2
Here we depart from the earlier approaches and describe a scalable amorphous dielectric polymer with a low-entropy of molecular conformations, which was prepared by using a general polymer blending strategy. The low-entropy amorphous polymer comprising high-Tg poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) blended with polystyrene (PS) exhibits superior capacitive performance at elevated temperature and high applied electric field. The rationale of our material design is that by using strong van der Waals interactions between the phenyl ring of the PS and the phenylene ring of PPO to “stretch” the main chain at the molecular level, we achieve a significant reduction of molecular conformation entropy in an amorphous polymer with randomly oriented yet superiorly packed extended polymer chains, which can inhibit charge transport via deep-level localized states. This is different from the reported high-temperature polymer nanocomposites which only tune conformation and arrangement of the polymer chain in the particle/matrix interface. Consequently, such a low-entropy amorphous dielectric polymer exhibits a discharged energy density of 5.5J cm−3 with a charge–discharge efficiency of >90% at 150 °C, outperforming the existing dielectric polymers and showing a more than two-fold increase in discharged energy density compared to polyetherimide (PEI), one of the best high-temperature dielectric polymers.6 Moreover, compared to reported approaches, the film processing, i.e., polymer blending, is very simple, straightforward and low cost; thus the approach presented paves the way for mass fabrication of high-performance and high-quality polymer films required for high-temperature film capacitors.
Fig. 1 Structures and structural characterization of low-entropy films. (A) Glass transition temperature (Tg) of PPO/PS blends versus PS content. The experimental Tg of the samples was deduced from DSC curves as shown in Fig. S1 (ESI†). The dashed line in (A) represents the fitting of Tg using the Flory–Fox equation , where Tg1 and Tg2 are the Tgs of polymer 1 and polymer 2, respectively, and w1 and w2 are their corresponding weight percentages in the blends. Taping-mode AFM data for the PPO/PS 75%/25% blend, phase (B) and topography (C) images with a scanning area of 10 × 10 μm. (D) FT-IR spectra in the region 1220–1140 cm−1 of PPO/PS blends with different blending ratios. (E) Excess interchain spacing of PPO/PS blends calculated from the peak positions of the X-ray profiles in Fig. S5 (ESI†) versus PS content. (F) Density of PPO/PS blends versus PS content. (G) Change in specific heat capacity during glass transition (ΔCp) for PPO/PS blends with different ratios. (H) elastic moduli of neat PPO, PS and the 75%/25% PPO/PS blend. |
The conformations of the polymer chains and the packing behavior in the blends were evaluated experimentally. FT-IR spectroscopy was employed to characterize chain conformation in PPO/PS blends, and the spectral data are presented in Fig. 1D and Fig. S4 (ESI†). We noticed that the band widths associated with these vibrational transitions are narrower in the polymer blends than in the homopolymers (Fig. 1D). It suggested that the conformational freedom or at least the distribution of conformations available to PPO in blends is limited compared to the neat PPO, and the degree of conformational freedom available to neat PPO is high.22,23 The conformation of the PPO chain is relevant to the conjugation of benzene π electrons that is, in any aromatic ether the conjugation of the benzene π electrons with the lone-pair electrons on the oxygen depends upon the angle the plane of the benzene ring makes with the plane of the C–O–C bond.22 The greatest conjugation occurs at 0° while the lowest occurs at 90°, which means that the locally extended polymer chain conformation is beneficial for the conjugation of benzene π electrons and makes the system more stable. X-ray diffraction (XRD) data revealed that the 75%/25% PPO/PS blend exhibits a broad amorphous scattering peak at the 2θ angle of 13.1° (Fig. S5, ESI†). The corresponding interchain spacing is smaller than the value predicted by the linear relationship to the PPO and PS blending ratio. A 75%/25% PPO/PS blend exhibited the largest excess distance (i.e., the deviation of the actual interchain spacing from the theoretical interchain spacing based on linear relationship) among all the blends (Fig. 1E).
The density of the blend films was also measured, and the 75%/25% PPO/PS blend exhibited the highest density, which was 1.08 g cm−3, higher than 0.96 g cm−3 for neat PPO films and 0.91 g cm−3 for the neat PS films used in this study (Fig. 1F). Fig. 1G revealed that the change in specific heat capacity (ΔCp) during the glass transition was the lowest as the content of PS approaches 0.25. In general, a change of polymer chain conformation from a highly self-entangled state to an extended backbone state is the primary contributor to the ΔCp during a polymer's glass transition. Therefore, the minimum ΔCp of the blend with PPO/PS 75%/25% ratio (Fig. 1G) implied that PPO backbones are more extended for this blend compared with pristine polymers and other blends before the glass transition.24 Our results showed that the blend film of 75%/25% PPO/PS ratio has the most extended polymer chain conformation among all the blend compositions of PPO and PS studied, which leads to the lowest ΔCp and the largest excess interchain distance as observed in XRD. Clearly, the deformed extended chain-packing morphology improves the packing density. Increased elastic modulus and thermal conductivity of the blend, compared with PPO and PS, were also observed (Fig. 1H and Fig. S7, ESI†), and were consistent with the more extended chain-packing morphology and the increase in density. These results illustrate that the mechanical and thermal performance of dielectric polymers can also be tuned and improved by the low-entropy polymer chains with locally extended conformation.
We then measured the leakage current and breakdown properties of the low-entropy films and compared them with the neat PPO films at elevated temperatures. The leakage current density of the low-entropy film of PPO/PS 75%/25% is suppressed by more than two orders of magnitude compared with that of the neat PPO film, for example, 3.09 × 10−8 A cm−2 for the PPO/PS 75%/25% compared with and 1.78 × 10−6 A cm−2 of the neat PPO at an electric field of 300 MV m−1 and the temperature of 150 °C (Fig. 3A). Fig. 3B shows the temperature-dependent electrical conductivity, indicating that PPO/PS (75%/25%) exhibits the highest activation energy (0.99 eV) compared to pristine PPO (0.92 eV) and PS (0.84 eV). This suggests the greatest charge carrier trap depth in the low-entropy PPO/PS (75%/25%) blend. We derived the characteristic breakdown strength Eb of the low-entropy film from the Weibull distribution analysis which is presented in Fig. 3C. An Eb of 662 MV m−1 was achieved in the low-entropy films of PPO/PS 75%/25% at a temperature of 150 °C, which is substantially enhanced by 65.5% compared to the neat PPO of Eb of 400 MV m−1 and is higher than those of most of currently reported high-temperature polymers, for example, 377 MV m−1 of PEI,11 400 MV m−1 of PEEU17 and 641 MV m−1 of CS-ODA25 (Fig. 3D). The large enhancement of breakdown strength of the low-entropy film compared to the neat PPO is consistent with the increased Young's modulus originating from the dense packing of low-entropy polymer chains and significantly decreased leakage current, as described by the widely accepted dielectric breakdown mechanisms.26
To understand the mechanisms of the greatly decreased leakage current density and improved breakdown strength in the low-entropy PPO/PS 75%/25% film, we studied the charge transport behavior through analysis of the current density using different conduction models.27 As shown in the fitting curves in Fig. 3A, the J–E data of the neat PPO and the low-entropy PPO/PS 75%/25% were fitted well by the hopping conduction model with a coefficient of determination (R2) both larger than 0.99, implying that hopping conduction is the predominant conduction mechanism at high temperatures and high electric fields for the tested samples. The derived hopping distance (λ) decreases from 0.76 nm in the neat PPO to 0.52 nm in the 75%/25% PPO/PS blend. The energy gained by mobile charges between two traps is directly proportional to the hopping distance λ. The significantly reduced hopping distance λ reduces the energy gained by mobile charges, thereby improving the breakdown strength and lowering conduction losses.28,29 These experimental results indicate that the low-entropy amorphous microstructure of the polymer blend, which is short-range ordered but long-range disordered, effectively scatters charge carriers and inhibits the transport of mobile electrons (Fig. 3E). Consequently, this reduces the leakage current density and enhances the dielectric breakdown strength.
Considering the practical applications, we evaluated the performance reliability and self-healing capability of our low-entropy amorphous polymer films. In the cycling reliability test, the films were charged and discharged repeatedly over 30000 cycles at an electric field of 400 MV m−1 (much higher than that under the operating condition, i.e., 200 MV m−1, of capacitors in common power systems such as electric vehicles) and a temperature of 150 °C. The energy storage properties are presented in Fig. 4D. The low-entropy amorphous polymer film with the PPO/PS composition of 75%/25% survive after 30000 cycles with a slight performance degradation, that is, ≤0.6%% for Ue with η maintained at >95% whereas the neat PPO showed low cycling reliability and breakdown in less than 64 cycles at 150 °C and 400 MV m−1. We attribute the excellent cycling reliability to the low leakage current density and high breakdown strength in the low-entropy films, which will promote the broad applicability of these dielectric capacitors.
The PPO/PS 75%/25% film capacitor also exhibits excellent self-healing capability. As evidenced by scanning electron microscopy (SEM) images and energy-dispersive spectroscopy (EDS) mapping (Fig. 4E), after a breakdown occurred in a metalized PPO/PS 75%25% film, the electrodes were mostly evaporated and the carbonization area was isolated at the breakdown hole. Therefore, no conductive path was formed between the carbonized breakdown hole and the electrodes in the low-entropy amorphous polymer. Subsequently, we showed that, following a dielectric breakdown, PPO/PS 75%/25% worked normally in the next charge–discharge cycle, with tiny decreases in Ue (from 2.3 to 2.1 J cm−3) and η (from 96.3% to 93.2%) at 150 °C (Fig. 4F). It is empirically understood that, for a polymer with the general formula CαHβOγNδSθ, a low ratio of (α + δ + θ) to (β + γ) typically enables the polymer molecules to decompose into gas with less residue of deposited carbon during electric breakdown, and yields a good self-healing ability.38 In this sense, the self-healing of PPO/PS 75%/25% capacitor attributed to the low ratio of (α + δ + θ) to (β + γ), this is 0.89 and 1.0 for PPO and PS, respectively, much lower than those of the aromatic polymer dielectrics, including PEI (1.3), polyimides (1.6) and PEEK (1.33).6 The excellent breakdown self-healing capability of PPO/PS 75%/25% offers high reliability to its metallized film capacitors for the practical applicability.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d4ee02455a |
This journal is © The Royal Society of Chemistry 2024 |