Experimental, Simulation and Theoretical Insights into Anisotropic Thermal Behavior of Epoxy Nanocomposites Reinforced with Carbonaceous Nanofillers

Understanding and optimizing thermal conductivity in epoxy-based composites is crucial for efficient thermal management applications. This study investigates the anisotropic thermal conductivity of a tetra-functional epoxy resin filled with low concentrations (0.25–2.00 wt%) of carbonaceous nanofillers: 1D multiwall carbon nanotubes (MWCNTs) and 2D exfoliated graphite (EG) nanoparticles. Experimental measurements conducted using the Transient Plane Source (TPS) method reveal distinct behaviors depending on the nanofiller’s geometry. Epoxy formulations incorporating MWCNTs exhibit a ~60% increase in in-plane thermal conductivity (λI-p dir.) compared to the unfilled resin, with negligible changes in the through-plane direction (λT-p dir.). Conversely, EG nanoparticles enhance thermal conductivity in both directions, with a preference for the in-plane direction, achieving a ~250% increase at 2 wt%. In light of this, graphene-based fillers establish a predominant thermal transport direction in the resulting nanocomposites due to their layered structure, whereas MWCNTs create unidirectional thermal pathways. The TPS results were complemented by multiphysics simulations in COMSOL and theoretical studies based on the theory of thermal circuits to explain the observed phenomena and justify the experimental findings. This integrated approach, combining experiments, theoretical analyses, and simulations, demonstrates the potential for tailoring the thermal properties of epoxy nanocomposites. These insights provide a foundation for developing advanced materials optimized for efficient thermal management in high-performance systems.