MELT VISCOSITY INDEX

The melt viscosity of polymers is usually measured as the melt flow index (MFI), also known as melt viscosity index (MVI) and melt flow rate (MFR). A pressure is applied to force the molten polymer through a hole at a controlled temperature [24]. All three parameters are set out in standards appropriate to the polymer being measured [24]. The measured value is in grams of polymer extruded through the hole in a set period of time, e.g., ten minutes. This of course, is actually the reciprocal of the viscosity, so a high MFI means low viscosity and vice versa. 

Melt Index or Melt Viscosity. Melt index describes the flow behavior of a polymer at a specific temperature under specific pressure. If the melt index is low, its melt viscosity or melt flow resistance is high the latter is a term that denotes the resistance of molten polymer to flow when making film, pipe, or containers. ASTM D1238 is the designated method for this test. 

MFI = melt flow index IV = intrinsic viscosity in CH2CI2 at 25°C From gel-permeation chromatography using polystyrene standards. 

The flow process in an injection mould is complicated by the fact that the mould cavity walls are below the freezing point of the polymer melt. In these circumstances the technologist is generally more concerned with the ability to fill the cavity rather than with the magnitude of the melt viscosity. In one analysis made of the injection moulding situation, Barrie showed that it was possible to calculate a mouldability index (p.) for a melt which was a function of the flow parameters K and the thermal diffusivity and the relevant processing temperatures (melt temperature and mould temperature) but which was independent of the geometry of the cavity and the flow pattern within the cavity. 

With the availability of the higher density polymers the value of the melt flow index as a measure of molecular weight diminishes. For example, it has been found that with two polymers of the same weight average molecular weight (4.2 X 10 ), the branched polymer (density = 0.92 g/cm ) had only 1/50 the viscosity of the more or less unbranched polymer (density = 0.96 g/cm ). This is due to long chain branches as explained above. 

The melt flow index describes the viscosity of a solid plastic. It is the weight in grams of a polymer extruded through a defined orifice at a specified time. The melt viscosity and the melt flow index can measure the extent of polymerization. A polymer with a high melt flow index has a low melt viscosity, a lower molecular weight, and usually a lower impact tensile strength. 

The melt index (MI) or melt flow index (MFT) is an inverse measure of viscosity. High MI implies low viscosity and low MI means high viscosity. Plastics are shear thinning, which means that their resistance to flow decreases as the shear rate increases. This is due to molecular alignments in the direction of flow and disentanglements. 

Some properties, such as heat capacity, refractive index, and density, are not particularly sensitive to molecular weight but many important properties are related to chain length. Figure 3.2 lists three of these. The melt viscosity is typically proportional to the 3.4 power of the average chain length so 17 is proportional to Thus, the melt viscosity increases rapidly... 

Two main types of viscometers are suitable for the determination of the viscosity of a polymer melt The rotation viscometer (Couette viscometer, cone-plate viscometer) and the capillary viscometer or capillary extrusiometer. The latter are especially suitable for laboratory use since they are relatively easy to handle and are also applicable in the case of high shear rates. With the capillary extrusiometer the measure of fluidity is not expressed in terms of the melt viscosity q but as the amount of material extruded in a given time (10 min). The amount of ex-trudate per unit of time is called the melt index or melt flow index i (MFI). It is also necessary to specify the temperature and the shearing stress or load. Thus MFI/2 (190 °C)=9.2 g/10 min means that at 190 °C and 2 kg load, 9.2 g of poly-... 

Another thermal property which is of great industrial importance is the melt viscosity, characterized, e.g., by the melt flow index, MFI, or the melt flow rate, MFR (see Sect. 2.3.4.6). The melt viscosity is first of all influenced by the molecular weight according to ... 

The melt flow index is a useful indication of the molar mass, since it is a reciprocal measure of the melt viscosity p. p depends very strongly on 77 ( ) (doubling of results in a 10.6 times higher 77 ). This relation is valid for the zero-shear viscosity the melt index is measured at a shear stress where the non-Newtonian behaviour, and thus the width of the molar mass distribution, is already playing a part (see MT 5.3.2). The melt index is a functional measure for the molar mass, because for a producer of end products the processability is often of primary importance. 

The T of crystalline polymers may be determined by observing the first-order transition (change in heat capacity value) by DTA or by DSC (ASTM-D3418). Some comparative information on thermal properties of polyolefins may be obtained from the melt index. To determine the melt index, the weight of extrudate or strand under a specified load and at a specified temperature is measured. Melt index values are inversely related to the melt viscosity. 

Most processing techniques are carried out in the fluid phase. Here the melt viscosity is the most important parameter. Often this is expressed as the melt index (m.i., see 2.2.3 and 5.3.1), which is a measure for the reciprocal viscosity for a given value... 

Some of the test methods being used to measure the processing stability of polypropylene include melt flow drift measurements at elevated temperatures using an extrusion plastometer (melt indexer), melt viscosity retention measurements using a torque rheometer, retention of melt flow after repeated extrusions, and injection molded spiral test measured by the flow in inches at various temperatures and the retention of melt flow of the injected spirals. The nine commercial resins were evaluated by these methods. 

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