Thermoplastic Polyurethane/ZnO Composites Simply Prepared from Solution Casting and Proposed as Thermally Conductive Gaskets for Energy Storage Technology and Energy Applications

In the study, a thermoplastic polyurethane composite is formulated and proposed as a gasket used in energy storage technology and energy applications. Due to the high preparation cost of thermally conductive composite gaskets, the composite materials were prepared through inexpensive solution casting and monitored in their thermal conductivity, mechanical properties and morphology. The specimens were also tested in a fluid resistance test and a hot water immersion test. The thermal conductivity of the proposed composite gaskets is in the range of 0.1–0.2 Wm–1K–1. An increase in ZnO loading enhances shore A hardness and Young’s modulus whereas it decreases in %elongation at break. However, tensile strength and tear strength remain unaffected. Scanning electron microscope (SEM) images and SEM combined with Energy Dispersive X-ray analysis (EDX) reveal that the prepared composites demonstrate enhanced thermal conductivity, attributed to a higher filler content and minimized distances between conductive particles. With thicknesses ranging from 1.40 to 1.85 mm, their physical appearance, weight loss and thermal conductivity were not significantly changed after fluid immersion and water immersion at 70 °C. Consequently, the composite samples developed in the study are proposed as promising candidates for use in energy storage technologies and related applications.