Thermally conductive but electrically insulating materials are highly desirable for thermal management applications in electrical encapsulation and future energy fields, for instance, superconducting magnet insulation in nuclear fusion systems. However, the traditional approaches usually suffer from inefficient and anisotropic enhancement of thermal conductivity or deterioration of electrical insulating property. In this study, using boron nitride sphere (BNS) agglomerated by boron nitride (BN) sheets as fillers, we fabricate a series of epoxy/BNS composites by a new approach, namely gravity-mix, and realize the controllable BNS loading fractions in the wide range of 5–40 wt%. The composites exhibited thermal conductivity of about 765% and enhancement at BNS loading of 40 wt%. The thermal conductivity up to 0.84 W·m⁻¹·K⁻¹ at 77 K and 1.66 W·m⁻¹·K⁻¹ at 298 K was observed in preservation of a higher dielectric constant and a lower dielectric loss, as expected, because boron nitride is a naturally dielectric material. It is worth noting that the thermal property was almost isotropous on account of the spherical structure of BNS in epoxy. Meanwhile, the reduction of the coefficient of thermal expansion (CTE) was largely reduced, by up to 42.5% at a temperature range of 77–298 K.

The present work describes the monitoring system of the real-time strain response on the curing process of epoxy resin from the initial point of curing to the end, and the change in strain during temperature changes. A simple mould was designed to embed the strain gauge, thermometer, and quartz standard sample into the epoxy resin, so that the strain and the temperature were simultaneously measured and recorded. A cryogenic-grade epoxy resin was tested and the Differential Scanning Calorimetry (DSC) was used to analyse the curing process. Based on the DSC results, three curing processes were adopted to investigate their influence on strain response as well as residual strain of the epoxy resin. Moreover, impact strength of the epoxy resin with various curing temperatures were tested and the results indicate that the curing plays a crucial role on the mechanical properties. The method will find cryogenic application of epoxy adhesives and epoxy resin based composites to monitor the strain during the curing process as well as the cryogenic service.

Epoxy-based composites are crucial insulating and structural materials for superconducting magnets, providing mechanical strength, winding fixation, and heat transfer. However, future superconducting devices with higher integration and power will place even higher demands on their toughness, thermal conductivity, electrical insulation, and radiation resistance at low temperatures. Otherwise, problems such as cracking, detachment, and low heat dissipation efficiency will arise, which may lead to quenching of low-temperature superconductors (Nb₃Sn, NbTi) and a decline in the performance of high-temperature superconductors (YBCO). Research focuses on summarizing the recent progress in modifying epoxy resin to address these issues. The current strategies include formula optimization using mixed curing and toughening agents to enhance mechanical properties, incorporating functional fillers to improve cryogenic thermal conductivity and reduce the coefficient of thermal expansion. Studies also evaluate cryogenic electrical insulation performance (DC breakdown strength, flashover voltage) and radiation resistance under cryogenic conditions. These advancements aim to develop reliable epoxy composites, ensuring the stability and safety of superconducting magnets in applications such as particle accelerators and fusion reactors.