Three-Dimensional Thermal Conductive Modeling of Hybrid Thermal Conductive Powders Filled POK-Based Composites

High Resolution Image Download MS PowerPoint Slide This study investigates the development of polyketone (POK)–based composites reinforced with various thermally conductive fillers─including synthetic graphite (SG), carbon fiber (CF), carbon nanotubes (CNTs), and hexagonal boron nitride (BN)─and combinations thereof. Single-, binary-, and ternary-filler systems were fabricated to examine the influence of filler type, morphology, concentration, and interactions on the resulting thermal conductivity. A three-dimensional analytical thermal conduction model was developed to predict the effective thermal conductivity of the composites, incorporating filler anisotropy, fiber orientation, interfiller interactions, and multifiller synergy. Fiber orientation distributions were obtained using Moldex3D simulations and integrated into the model. The in-plane thermal conductivity increased from 0.21 W/mK for neat POK to as high as 9.16 W/mK with 40 wt % synthetic graphite, while carbon fiber–reinforced composites reached 8.54 and 1.12 W/mK in in-plane and through-plane directions, respectively. BN–CNT hybrid systems exhibited synergistic improvements even at low loadings. Model predictions showed strong agreement with experimental values, validating the reliability of the proposed approach. The graphical comparison demonstrates strong agreement between model predictions and experimental results across all filler systems, with deviations remaining within ± 10% for fiber-reinforced composites and within ± 5% for particle-filled systems. These findings offer practical guidance for the design and optimization of lightweight, thermally conductive composites for advanced thermal management applications.