Unsaturated polyester/graphite composite for electronic casings and electrical insulation: juggling mechanical strength, thermal stability, and flame retardance

General Purpose unsaturated polyester Resin (GPR)/graphite composites were prepared by dispersing varying concentrations of graphite in GPR. The chemical structure, crystallinity, morphology, and thermal stability of the composites were analyzed using IR, XRD, SEM, DSC, and TGA. mechanical, dielectric, and corrosion resistance properties. According to the final outputs of the thorough property evaluation of GPR/graphite, the addition of graphite as a filler material improved GPR overall. Composites containing at least 3% graphite were found to be self-extinguishable based on the limiting oxygen index (LOI). The hardness of GPR composites increased with higher graphite content. Tensile strength tests showed that the composite designated as A4 is suitable for industrial applications. Composite A3, with 3% graphite, exhibited the highest flexural strength (80.5 MPa), compressive strength (90.1 MPa), and lowest compression (7.52%). Dielectric strength measurements were also reported. DSC analysis provided the specific heat capacity (ΔCp) and glass transition temperature (Tg). Chemical resistance tests revealed maximum resistance to toluene and minimum to sodium hydroxide for all samples (A1 to A4). This propels the scope of (GPR)/graphite composite application in the electrotechnical area, mainly due to its dielectric property being enhanced, along with its flame retardancy, thermal stability and mechanical strength.