Development and Characterization of Thermo Mechanically Improved AlN – ABS Composites for Potential Application in Battery Modules

ABSTRACT Advanced polymer composites with tailored thermal, mechanical, and flame‐retardant properties are increasingly explored for applications in transportation, electronics, and energy storage systems. Herein, a novel acrylonitrile butadiene styrene (ABS) polymer composite reinforced with dispersed aluminium nitride (AlN) is developed and systematically characterized in microstructural, thermal, and mechanical domains to evaluate its multifunctional performance. Field emission scanning electron microscopy (FE‐SEM) and energy dispersive spectroscopy (EDS) confirm uniform dispersion of AlN. The composite exhibits enhanced thermal stability and improved thermal conductivity, facilitating heat dissipation, as evidenced by TGA‐DSC and laser flash analysis (LFA). Flame‐retardant behavior is demonstrated by achieving a UL‐94 V‐1 rating. Mechanical characterization reveals a peak tensile strength of 44.18 MPa and a tensile modulus of 1240 MPa at 3 wt.% AlN loading, corresponding to improvements of 14.7% and 23.2%, respectively, compared to neat ABS. Flexural strength increases by 16.23%, while a 12% reduction in impact strength is observed, representing an acceptable trade‐off for enhanced flame retardancy. It is to be emphasized that enhanced thermo mechanical and flame‐retardant properties are essential requirements for safer battery modules. The results and underlying hypothesis discussed herein support the conclusion that the developed material can effectively replace existing battery spacer materials in lithium‐ion battery (LIB) module.