BaTiO3/polymer/Al (BPA) composite films for energy storage were fabricated by way of a roll coating and thermal curing process. The coating slurry consisted of silicon-containing heat-resistant resin (CYN-01) and BaTiO3 particles with various particle sizes obtained from commercial BaTiO3 powders processed at different durations of wet sand grinding in the presence of silane coupling agent (KH550), which not only improves the dielectric performance of the BPA films but also facilitates its production in a large scale. The major influence factors, such as the ratio between BaTiO3 and resin and the size of BaTiO3 particles, were investigated and their related mechanisms were discussed. The results show that modifying BaTiO3 particles (D90 = 0.83 μm) with the silane coupling agent of KH550 enhances the dielectric properties of the BPA films. The typical BPA films obtained exhibit a high dielectric constant of 32, a high break strength of 20.8 V/μm and a low dielectric loss of 0.014. The present work provides a simple and convenient way to prepare high-quality ceramic/polymer composite films for energy-storage application in a large scale.

Simple but robust growth of spherical BaTiO3 nanoparticles with uniform nanoscale sizes is of great significance for the miniaturization of BaTiO3-based electron devices. This paper reports a TiO2-seeded hydrothermal process to synthesize spherical BaTiO3 nanoparticles with a size range of 90–100 nm using TiO2 (Degussa) and Ba(NO3)2 as the starting materials under an alkaline (NaOH) condition. Under the optimum conditions ([NaOH] = 2.0 mol L−1, RBa/Ti = 2.0, T = 210 °C and t = 8 h), the spherical BaTiO3 nanoparticles obtained exhibit a narrow size range of 91 ± 14 nm, and the corresponding BaTiO3/polymer/Al film is of a high dielectric constant of 59, a high break strength of 102 kV mm−1, and a low dielectric loss of 0.008. The TiO2-seeded hydrothermal growth has been proved to be an efficient process to synthesize spherical BaTiO3 nanoparticles for potential capacitor energy-storage applications.

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The process of suspension polymerization was utilized to create acrylate resin microspheres with mesh numbers of 140–200 μm and particle sizes of 100 μm for implementation in mesh coating technology. The copolymer of methyl methacrylate (MMA) and methyl acrylate (MA) served as the primary polymer, with dibenzoyl peroxide (DBPO) functioning as the initiator, and a mixture of calcium carbonate and deionized water served as the dispersion medium. The surface morphology of the synthesized microspheres was analyzed through Fourier-transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM) to confirm successful synthesis. The optimal reaction conditions for the synthesis of these microspheres were determined to be a dispersant dosage of 30 g of calcium carbonate with a monomer ratio of 4:1, a reaction time of 1 h, an initiator dosage of 1.2 g of BPO, and a reaction temperature of approximately 75–80 C, resulting in microspheres with a regular spherical shape and smooth surface.