Particle size distribution, fillers

For large amounts of fillers, the maximum theoretical loading with known filler particle size distributions can be estimated. This method (8) assumes efficient packing, ie, the voids between particles are occupied by smaller particles and the voids between the smaller particles are occupied by stiH smaller particles. Thus a very wide filler psd results in a minimum void volume or maximum packing. To get from maximum packing to maximum loading, it is only necessary to express the maximum loading in terms of the minimum amount of binder that fills the interstitial voids and becomes adsorbed on the surface of the filler. 

To lower the probability of conduction in the X Y plane (i.e., reduce the short-range percolation coherence length ), particles are used with an aspect ratio as close to 1 as possible. In contrast, isotropically conductive systems use flakes with high aspect ratios as fillers. Particle size distributions are minimized so that each particle can potentially serve as an electrical bridge between substrate and device. 

Table 8.1 Characteristics of filler particles investigated to study the effect of filler particle size distribution (PSD)...

Several properties of the filler are important to the compounder (279). Properties that are frequentiy reported by fumed sihca manufacturers include the acidity of the filler, nitrogen adsorption, oil absorption, and particle size distribution (280,281). The adsorption techniques provide a measure of the surface area of the filler, whereas oil absorption is an indication of the stmcture of the filler (282). Measurement of the sdanol concentration is critical, and some techniques that are commonly used in the industry to estimate this parameter are the methyl red absorption and methanol wettabihty (273,274,277) tests. Other techniques include various spectroscopies, such as diffuse reflectance infrared spectroscopy (drift), inverse gas chromatography (igc), photoacoustic ir, nmr, Raman, and surface forces apparatus (277,283—290). 

The functions of the filler and the binder are to provide physical integrity (density, attrition resistance, particle size distribution, etc.), a heat transfer medium, and a fluidizing medium in which the more important and expensive zeolite component is incorporated. 

However, the chief purpose of introduction of fillers into PCM is to make possible the modification of polymers and thereby create materials with a prescribed set of physico-mechanical properties, and, obviously, the properties of filled materials may be controlled by, for example, varying the type of the base polymer (the matrix ) and filler, its particle size distribution and shape. It may not require a large quantity of filler [7]. Thanks to considerable advances in PCM research, their use in a broad range of industries — machine building, construction, aerospace technology, etc. — has become extensive [8 — 11]. 

In HDPE and LDPE matrices, the introduction of PMF with polyethylene coats affects the viscosity in such a way that is independent of the nature and particle size distribution of the mineral filler employed and depends only on NMF particle size. All other conditions identical, this effect is the same as that of the particles of standard high-molecular PE [164, 297, 298]. 

The most challenging part of rubber mixing is the dispersion of the filler The filler agglomerates have to be broken into smaller particles, the aggregates, but not completely to the level of primary particles. An optimal particle size distribution has to be achieved in order to obtain the best properties of the final rubber product [14]. 

Table 6.3 Particle size distributions and surface areas of some common fillers.

Composite-based PTC thermistors are potentially more economical. These devices are based on a combination of a conductor in a semicrystalline polymer—for example, carbon black in polyethylene. Other fillers include copper, iron, and silver. Important filler parameters in addition to conductivity include particle size, distribution, morphology, surface energy, oxidation state, and thermal expansion coefficient. Important polymer matrix characteristics in addition to conductivity include the glass transition temperature, Tg, and thermal expansion coefficient. Interfacial effects are extremely important in these materials and can influence the ultimate electrical properties of the composite. 

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