Constructing Highly Ordered Continuous BNNS Networks in COP Film to Achieve Excellent Thermal Conduction and Dielectric Performance

To meet the requirement of thermal management of modern electronic devices, polymer composites with high thermal conductivity (TC) and dielectric performance are nowadays in urgent demand. Herein, a highly ordered continuous network of boron nitride nano-sheet (BNNS) was constructed in cyclic olefin polymer (COP) films via the forced flow processing in the rubbery state (FFRS), melt-spinning, fiber-alignment, and hot-pressing procedures. The composites exhibited superior TC, low dielectric permittivity, and low dielectric loss simultaneously. The in-plane TC of the composites reached 3.92 W/(mK) when the content of BNNS was at 27 weight percentage (27 wt%), since the procedures improved the face-to-face contact between the BNNS (which was exfoliated, dispersed, and in-plane oriented during FFRS), enhancing the continuity of the BNNS thermally conductive network. Both the TC and the experimental results indicated the outstanding heat dissipation performance of the composites. Meanwhile, the dielectric permittivity and dielectric loss of the 27 wt% BNNS composites were 2.56 and 0.00085 at 10 GHz, respectively, lower than that of the COP-POE matrix. Moreover, the mechanical properties, water vapor permeability, and coefficient of thermal expansion of the composites were excellent. The composites with such highly ordered continuous networks are very promising in high-performance electronic devices.