Filler Size Hybridization and Dielectrophoretic Structuring of Soft Polymer Based Thermally Conductive Composites

ABSTRACT This study offers a detailed exploration of the dielectrophoretic structuring of filler size hybrid thermally conductive composites, emphasizing the impact of filler size hybridization on the thermal and mechanical properties of PDMS‐Al 2 O 3 composites. By comparing the performance of monodisperse and hybrid composites, we highlight the advantages of size hybridization in optimizing composite properties. The results indicate significant improvements in thermal conductivity and mechanical stiffness due to enhanced filler packing density and more efficient structuring. Our investigation into various compositions and size ratios reveals optimal thermal properties at specific hybridization levels, suggesting key parameters for superior composite performance. These results demonstrate the advantage of combining size hybridization with dielectrophoretic structuring to design advanced composites for thermal management, while emphasizing the need for future studies to tackle environmental concerns and investigate alternative polymer matrices.