Electrical Characterization of Boron Nitride-Filled Insulation for Aerospace and Avionics Applications

The environmental challenges associated with high-power, high-voltage electrified aircraft require a targeted approach with regard to the development of next-generation aerospace electrical insulation. This study reports findings on polyphenylsulfone (PPSU) as a matrix material based on its unique thermal, mechanical, and dielectric properties, filled with hexagonal boron nitride (h-BN) with micron- and nanoscale particulates. The inorganic ceramic filler was selected for its thermally conductive and electrically insulating performance in extreme environments. The main goal was to investigate the dielectric strength and electrical resistance (endurance) to partial discharges (PDs). Since PDs are a leading accelerated degradation phenomenon causing premature failure in organic electrical insulation, the capability of an insulating material to endure PD-induced degradation for the whole (or part of) its design life is of paramount importance. It was observed that incorporation of h-BN micro fillers can significantly improve the PD resistance, even in comparison with insulating materials typically used for electrified transportation, such as corona-resistant Kapton. It was also observed that a suitable combination of micro and nano fillers can also be used as a viable solution to increase the electrical performance and reliability of the avionics insulation components.