A Comparative Study of Gypsum-Based Composites with Waste Recycling for Electrical Properties in Futuristic Applications

This research aims to evaluate the electrical insulation capabilities of gypsum composites fortified with varying ratios of recyclable waste materials through dielectric constant testing. Vermiculite (Vrm) and rigid polyurethane (RPU) powder were integrated into a gypsum (Gp) matrix using ball milling and fabricated via blend-press-sinter methodology. Utilizing response surface methodology (RSM) with central composite design (CCD), the weight percentages of the optimized sample were predicted, with dielectric constant (DC) values as the response output. In a meticulous examination of structural integrity and uniformity, a cutting-edge high-resolution scanning electron microscope (HR-SEM) was employed. The findings unveil an optimal DC value of 1.023 for a composition comprising 6.5wt.% vermiculite, 10wt.% rigid PU, and 83.5wt.% gypsum. These findings underscore the potential of gypsum-composites filled with recyclable waste materials such as vermiculite and rigid polyurethane powder offer versatile insulation with tailored dielectric constants, find applications in building insulation, electrical enclosures, and electronic packaging, ensuring efficient energy usage and electrical safety and also these materials are essential for high-voltage equipment, microwave absorbers, and antenna design, where precise dielectric properties are crucial for optimal performance.