With the development of electronic appliances and electronic equipment towards miniaturization, lightweight and high-power density, the heat generated and accumulated by devices during high-speed operation seriously reduces the working efficiency and service life of the equipment. The key to solving this problem is to develop high-performance thermal management materials and improve the heat dissipation efficiency of the equipment. This paper mainly summarizes the research progress of polymer composites with high thermal conductivity and electrical insulation, including the thermal conductivity mechanism of composites, the factors affecting the thermal conductivity of composites, and the research status of thermally conductive and electrical insulation polymer composites in recent years. Finally, we look forward to the research focus and urgent problems that should be addressed of high-performance thermal conductive composites, which will provide strategies for further development and application of advanced thermal and electrical insulation composites.

In this paper, we report a thermal conductive polymer composite that consists of silicone rubber (SR) and branched Al₂O₃ (B-Al₂O₃). Owing to the unique two-dimensional branched structure, B-Al₂O₃ particles form a continuous three-dimensional network structure by overlapping each other in the matrix, serving as a continuous heat conductive pathway. As a result, the polymer composite with a 70 wt% filler achieves a maximum thermal conductivity of 1.242 Wm⁻¹ K⁻¹, which is equivalent to a significant enhancement of 521% compared to that of a pure matrix. In addition, the composite maintains a high volume resistivity of 7.94 × 10¹⁴ Ω·cm with the loading of 70 wt%, indicating that it meets the requirements in the field of electrical insulation. Moreover, B-Al₂O₃ fillers are well dispersed (no large agglomerates) and form a strong interfacial adhesion with the matrix. Therefore, the thermal decomposition temperature, residual mass, tensile strength, modulus and modulus of toughness of composites are significantly improved simultaneously. This strategy provides new insights for the design of high-performance polymer composites with potential application in advanced thermal management in modern electronics.

Metallic nanocrystals exhibit superior properties to their bulk counterparts because of the reduced sizes, diverse morphologies, and controllable exposed crystal facets. Therefore, the fabrication of metal nanocrystals and the adjustment of their properties for different applications have attracted wide attention. One of the typical examples is the fabrication of nanocrystals encased with high-index facets, and research on their magnified catalytic activities and selections. Great accomplishment has been achieved within the field of noble metals such as Pd, Pt, Ag, and Au. However, it remains challenging in the fabrication of base metal nanocrystals such as Ni, Cu, and Co with various structures, shapes, and sizes. In this paper, the synthesis of metal nanocrystals is reviewed. An introduction is briefly given to the metal nanocrystals and the importance of synthesis, and then commonly used synthesis methods for metallic nanocrystals are summarized, followed by specific examples of metal nanocrystals including noble metals, alloys, and base metals. The synthesis of base metal nanocrystals is far from satisfactory compared to the tremendous success achieved in noble metals. Afterwards, we present a discussion on specific synthesis methods suitable for base metals, including seed-mediated growth, ligand control, oriented attachment, chemical etching, and Oswald ripening, based on the comprehensive consideration of thermodynamics, kinetics, and physical restrictions. At the end, conclusions are drawn through the prospect of the future development direction.

Fouling is a great problem that significantly affects the continuous operation for large-scale radio-frequency (RF) thermal plasma synthesizing nanopowders. In order to eliminate or weaken the phenomenon, numerical simulations based on FLUENT software were founded to investigate the effect of operation parameters, including feeding style of central gas and sheath gas, on plasma torches. It is shown that the tangential feeding style of central gas brings serious negative axial velocity regions, which always forces the synthesized nanopowders to “back-mix”, and further leads to the fouling of the quartz tube. Moreover, it is shown that sheath gas should be tangentially fed into the plasma reactor to further eliminate the gas stream’s back-mixing. However, when this feeding style is applied, although the negative axial velocity region is decreased, the plasma gas and kinetic energy of the vapor phase near the wall of the plasma reactor are less and lower, respectively; as a result, that plasma flame is more difficult to be arced. A new plasma arcing method by way of feeding gun instead of torch wall was proposed and put in use. The fouling problem has been well solved and plasma arcing is well ensured, and as a result, the experiment on large-scale production of nanopowders can be carried out for 8 h without any interruption, and synthesized Si and Al₂O₃ nanopowders exhibit good dispersion and sphericity.

ZrB₂ is of particular interest among ultra-high temperature ceramics because it exhibits excellent thermal resistance at high temperature, as well as chemical stability, high hardness, low cost, and good electrical and thermal conductivity, which meet the requirements of high-temperature components of hyper-sonic aircraft in extreme environments. As raw materials and basic units of ultra-high temperature ceramics and their composites, ZrB₂ powders provide an important way for researchers to improve material properties and explore new properties by way of synthesis design and innovation. In recent years, the development of ZrB₂ powders’ synthesis method has broken through the classification of traditional solid-phase method, liquid-phase method, and gas-phase method, and there is a trend of integration of them. The present review covers the most important methods used in ZrB₂ nanopowder synthesis, focusing on the solid-phase synthesis and its improved process, including modified self-propagating high-temperature synthesis, solution-derived precursor method, and plasma-enhanced exothermic reaction. Specific examples and strategies in synthesis of ZrB₂ nano powders are introduced, followed by challenges and the perspectives on future directions. The integration of various synthesis methods, the combination of different material components, and the connection between synthesis and its subsequent application process is the trend of development in the future.