The mechanism of tuning filler orientation degree in composites based on AC electric field assist: from microscopic dynamical model to macroscopic electrical properties

Using the AC electric field to induce the orientation of nonlinear conductive fillers in composites is an effective solution for alleviating electric field distortion in power modules. However, the mechanism by which the electric field affects the filler dynamic characteristics and the composites’ electrical properties remains unclear. In this paper, the correlation between the microscopic dynamic processes of fillers and the macroscopic current amplitude was analyzed. The results show that the current increases rapidly (0 ∼ 173 s) and then slowly (173 ∼ 869 s) at 600 V mm⁻¹, influenced by the rotation and attraction processes of the fillers. This demonstrates that the orientation stops at about 869 s and the filler orientation state is a key factor in determining the dielectric properties. Secondly, the global orientation evaluation index D for the filler network was proposed, which can also derive the minimum time and energy loss required for preparation. Finally, the impact of different filler orientations on the composites’ conductivity was investigated. In the low electric field stress region, with the average carrier jump distance decreasing from 150.23 to 109.71 nm as the D increases from −0.93 to −0.05. On this basis, materials with nonlinear conductivity gradient distribution can be easily prepared. Before optimization, the electric field stress of the power module at the triple point was 35.79 kV. This composite can reduce the value to 15.42 kV, a decrease of 56.9%, while maintaining good electric field uniformity.