Mechanical and electrical properties of a polyester resin reinforced with clay-based fillers

In this study, composite polymer-based materials were fabricated, in which a significant proportion of polyester resin was substituted by low-cost and environmentally-friendly clay-based raw materials. The main objective is to improve mechanical properties while maintaining a reasonable electrical insulating behavior. A homogenized distribution of fillers within the matrix compatible with the processing parameters was obtained up to a maximum added fraction of 20 vol%. Mechanical characterization using uniaxial traction tests and Charpy impact pendulum machine showed that stress-to-rupture can be enhanced of approximately 25 %. In addition, fracture energy was doubled for the best formulation. Dielectric constant was decreased and loss factor was slightly increased when electrical resistivity remained almost constant. In general, the composite materials with metakaolin fillers exhibited higher mechanical properties and greater electrical insulating behavior. Microstructural observation showed the presence of decohesive agglomerates of particles at the interface with the matrix. The mechanical properties were found to be more sensitive than electrical properties to the homogeneity of filler dispersion in the matrix.