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Filled Polymers Science and Industrial Applications 1st Edition Jean L. Leblanc PDF Available

The document is about the book 'Filled Polymers: Science and Industrial Applications' by Jean L. Leblanc, which covers various aspects of filled polymers, including types of fillers, reinforcement concepts, and the effects of fillers on polymer properties. It provides insights into the applications of filled polymers in industrial settings and includes detailed references and appendices. The book is available in multiple digital formats for instant download.

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Filled
Polymers
Science and
Industrial
Applications
Filled
Polymers
Science and
Industrial
Applications

Jean L. Leblanc

Boca Raton London New York

CRC Press is an imprint of the


Taylor & Francis Group, an informa business
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2010 by Taylor and Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business

No claim to original U.S. Government works

Printed in the United States of America on acid-free paper


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International Standard Book Number: 978-1-4398-0042-3 (Hardback)

This book contains information obtained from authentic and highly regarded sources. Reasonable
efforts have been made to publish reliable data and information, but the author and publisher cannot
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publishers have attempted to trace the copyright holders of all material reproduced in this publication
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Contents

Preface.......................................................................................................................xi
Author Bio...............................................................................................................xv

1. Introduction....................................................................................................1
1.1. Scope of the Book...................................................................................1
1.2. Filled Polymers vs. Polymer Nanocomposites...................................3
References........................................................................................................8

2. Types of Fillers............................................................................................ 11

3. Concept of Reinforcement......................................................................... 15
Reference........................................................................................................ 19

4. Typical Fillers for Polymers...................................................................... 21


4.1 Carbon Black......................................................................................... 21
4.1.1 Usages of Carbon Blacks.......................................................... 21
4.1.2 Carbon Black Fabrication Processes....................................... 21
4.1.3 Structural Aspects and Characterization
of Carbon Blacks....................................................................... 24
4.1.4 Carbon Black Aggregates as Mass Fractal Objects..............30
4.1.5 Surface Energy Aspects of Carbon Black..............................44
4.2 White Fillers.......................................................................................... 49
4.2.1 A Few Typical White Fillers.................................................... 49
4.2.1.1 Silicates......................................................................... 49
4.2.1.2 Natural Silica............................................................... 52
4.2.1.3 Synthetic Silica............................................................ 53
4.2.1.4 Carbonates...................................................................54
4.2.1.5 Miscellaneous Mineral Fillers................................... 56
4.2.2. Silica Fabrication Processes..................................................... 56
4.2.2.1 Fumed Silica................................................................ 56
4.2.2.2 Precipitated Silica....................................................... 58
4.2.3 Characterization and Structural Aspects of
Synthetic Silica.......................................................................... 62
4.2.4 Surface Energy Aspects of Silica............................................ 68
4.3 Short Synthetic Fibers.......................................................................... 69
4.4 Short Fibers of Natural Origin........................................................... 72
References...................................................................................................... 79

v
vi Contents

Appendix 4.................................................................................................... 82
A4.1 Carbon Black Data............................................................................ 82
A4.1.1 Source of Data for Table 4.5............................................... 82
A4.1.2 Relationships between Carbon Black
Characterization Data........................................................84
A4.2 Medalia’s Floc Simulation for Carbon Black Aggregate.............85
A4.3 Medalia’s Aggregate Morphology Approach............................... 86
A4.4 Carbon Black: Number of Particles/Aggregate............................ 89

5. Polymers and Carbon Black...................................................................... 91


5.1 Elastomers and Carbon Black (CB).................................................... 91
5.1.1 Generalities................................................................................ 91
5.1.2 Effects of Carbon Black on Rheological Properties............. 95
5.1.3 Concept of Bound Rubber (BdR).......................................... 108
5.1.4 Bound Rubber at the Origin of Singular Flow
Properties of Rubber Compounds.......................... ............... 112
5.1.5 Factors Affecting Bound Rubber.......................................... 114
5.1.6 Viscosity and Carbon Black Level........................................ 121
5.1.7 Effect of Carbon Black on Mechanical Properties.............. 125
5.1.8 Effect of Carbon Black on Dynamic Properties.................. 140
5.1.8.1 Variation of Dynamic Moduli with Strain
Amplitude (at Constant Frequency and
Temperature)............................................................. 141
5.1.8.2 Variation of tan δ with Strain Amplitude and
Temperature (at Constant Frequency)...................142
5.1.8.3 Variation of Dynamic Moduli with
Temperature (at Constant Frequency and
Strain Amplitude)..................................................... 142
5.1.8.4 Effect of Carbon Black Type on G′
and tan δ.................................................................... 144
5.1.8.5 Effect of Carbon Black Dispersion on
Dynamic Properties................................................. 146
5.1.9 Origin of Rubber Reinforcement by
Carbon Black............................................................................ 148
5.1.10 Dynamic Stress Softening Effect.......................................... 151
5.1.10.1 Physical Considerations........................................... 151
5.1.10.2 Modeling Dynamic Stress Softening as a
“Filler Network” Effect............................................ 152
5.1.10.3 Modeling Dynamic Stress Softening as a
“Filler–Polymer Network” Effect........................... 168
5.2 Thermoplastics and Carbon Black................................................... 172
5.2.1 Generalities.............................................................................. 172
5.2.2 Effect of Carbon Black on Rheological Properties of
Thermoplastics........................................................................ 173
Contents vii

5.2.3 Effect of Carbon Black on Electrical Conductivity of


Thermoplastics........................................................................ 175
References.................................................................................................... 179
Appendix 5.................................................................................................. 185
A5.1 Network Junction Theory.............................................................. 185
A5.1.1 Developing the Model...................................................... 185
A5.1.2 Typical Calculations with the Network
Junction Model.................................................................. 188
A5.1.3 Strain Amplification Factor from the Network
Junction Theory................................................................. 190
A5.1.3.1 Modeling the Elastic Behavior
of a Rubber Layer between Two
Rigid Spheres................................................... 190
A5.1.3.2 Experimental Results vs.
Calculated Data................................................ 191
A5.1.3.3 Comparing the Theoretical Model with
the Approximate Fitted Equation.. .. ............ 192
A5.1.3.4 Strain Amplification Factor............................ 193
A5.1.4 Comparing the Network Junction Strain
Amplification Factor with Experimental Data............. 194
A5.2 Kraus Deagglomeration–Reagglomeration Model for
Dynamic Strain Softening............................................................. 196
A5.2.1 Soft Spheres Interactions................................................. 196
A5.2.2 Modeling G′ vs. γ0............................................................. 197
A5.2.3 Modeling G″ vs. γ0............................................................ 198
A5.2.4 Modeling tan δ vs. γ0........................................................ 200
A5.2.5 Complex Modulus G* vs. γ0............................................. 202
A5.2.6 A Few Mathematical Aspects of the
Kraus Model...................................................................... 204
A5.2.7 Fitting Model to Experimental Data.............................. 206
A5.2.7.1 Modeling G′ vs. Strain.................................... 207
A5.2.7.2 Modeling G″ vs. Strain.................................... 209
A5.3 Ulmer Modification of the Kraus Model for Dynamic
Strain Softening: Fitting the Model.............................................. 212
A5.3.1 Modeling G′ vs. Strain (same as Kraus)......................... 213
A5.3.2 Modeling G′′ vs. Strain..................................................... 215
A5.4 Aggregates Flocculation/Entanglement Model
(Cluster–Cluster Aggregation Model, Klüppel et al.)............... 218
A5.4.1 Mechanically Effective Solid Fraction
of Aggregate...................................................................... 219
A5.4.2 Modulus as Function of Filler Volume Fraction........... 220
A5.4.3 Strain Dependence of Storage Modulus........................ 221
A5.5 Lion et al. Model for Dynamic Strain Softening........................222
A5.5.1 Fractional Linear Solid Model.........................................222
viii Contents

A5.5.2 Modeling the Dynamic Strain Softening Effect...........223


A5.5.3 A Few Mathematical Aspects of the Model.................. 226
A5.6 Maier and Göritz Model for Dynamic Strain Softening........... 227
A5.6.1 Developing the Model...................................................... 227
A5.6.2 A Few Mathematical Aspects of the Model.................. 229
A5.6.3 Fitting the Model to Experimental Data........................ 230
A5.6.3.1 Modeling G′ vs. Strain.................................... 231
A5.6.3.2 Modeling G″ vs. Strain.................................... 232

6. Polymers and White Fillers..................................................................... 235


6.1 Elastomers and White Fillers........................................................... 235
6.1.1 Elastomers and Silica.............................................................. 235
6.1.1.1 Generalities................................................................ 235
6.1.1.2 Surface Chemistry of Silica..................................... 236
6.1.1.3 Comparing Carbon Black and (Untreated)
Silica in Diene Elastomers....................................... 237
6.1.1.4 Silanisation of Silica and Reinforcement of
Diene Elastomers...................................................... 239
6.1.1.5 Silica and Polydimethylsiloxane............................. 246
6.1.2 Elastomers and Clays (Kaolins)............................................ 257
6.1.3 Elastomers and Talc................................................................ 260
6.2 Thermoplastics and White Fillers.................................................... 262
6.2.1 Generalities.............................................................................. 262
6.2.2 Typical White Filler Effects and the Concept of
Maximum Volume Fraction.................................................. 266
6.2.3 Thermoplastics and Calcium Carbonates........................... 280
6.2.4 Thermoplastics and Talc........................................................ 291
6.2.5 Thermoplastics and Mica...................................................... 297
6.2.6 Thermoplastics and Clay(s)...................................................300
References.................................................................................................... 302
Appendix 6..................................................................................................308
A6.1 Adsorption Kinetics of Silica on Silicone Polymers...................308
A6.1.1 Effect of Polymer Molecular Weight..............................308
A6.1.2 Effect of Silica Weight Fraction....................................... 310
A6.2 Modeling the Shear Viscosity Function of Filled
Polymer Systems............................................................................. 312
A6.3 Models for the Rheology of Suspensions of Rigid Particles,
Involving the Maximum Packing Fraction Φm........................... 315
A6.4 Assessing the Capabilities of Model for the Shear
Viscosity Function of Filled Polymers......................................... 319
A6.4.1 Effect of Filler Fraction..................................................... 320
A6.4.2 Effect of Characteristic Time λ0...................................... 320
A6.4.3 Effect of Yasuda Exponent a............................................ 321
A6.4.4 Effect of Yield Stress σc................................................... 321
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Contents ix

A6.4.5
Fitting Experimental Data for Filled
Polymer Systems.............................................................. 322
A6.4.6 Observations on Experimental Data............................ 323
A6.4.7 Extracting and Arranging Shear
Viscosity Data.................................................................. 324
A6.4.8 Fitting the Virgin Polystyrene Data with the
Carreau–Yasuda Model.................................................. 324
A6.4.9 Fitting the Filled Polystyrene Shear Viscosity
Data................................................................................... 326
A6.4.10 Assembling and Analyzing all Results........................ 332
A6.5 Expanding the Krieger–Dougherty Relationship...................... 335

7. Polymers and Short Fibers...................................................................... 339


7.1 Generalities......................................................................................... 339
7.2 Micromechanic Models for Short Fibers-Filled Polymer
Composites..........................................................................................344
7.2.1 Minimum Fiber Length.........................................................344
7.2.2 Halpin–Tsai Equations...........................................................345
7.2.3 Mori–Tanaka’s Averaging Hypothesis and Derived
Models...................................................................................... 351
7.2.4 Shear Lag Models.................................................................... 353
7.3 Thermoplastics and Short Glass Fibers........................................... 358
7.4 Typical Rheological Aspect of Short Fiber-Filled
Thermoplastic Melts.......................................................................... 368
7.5 Thermoplastics and Short Fibers of Natural Origin..................... 370
7.6 Elastomers and Short Fibers............................................................. 375
References.................................................................................................... 383
Appendix 7.................................................................................................. 389
A7.1 Short Fiber-Reinforced Composites: Minimum Fiber
Aspect Ratio..................................................................................... 389
A7.1.1 Effect of Volume Fraction on Effective
Fiber Length...................................................................... 389
A7.1.2 Effect of Matrix Modulus on Effective
Fiber Length...................................................................... 390
A7.1.3 Effect of Fiber-to-Matrix Modulus Ratio on
Effective Fiber Length/Diameter Ratio......................... 391
A7.2 Halpin–Tsai Equations for Short Fibers Filled Systems:
Numerical Illustration.................................................................... 391
A7.2.1 Longitudinal (Tensile) Modulus E11............................... 392
A7.2.2 Transversal (Tensile) Modulus E22. ................................ 393
A7.2.3 Shear Modulus G12............................................................ 393
A7.2.4 Modulus for Random Fiber Orientation........................ 394
A7.2.5 Fiber Orientation as an Adjustable
Parameter. ......................................................................................394
x Contents

A7.2.6 Average Orientation Parameters from


Halpin–Tsai Equations for Short Fibers
Filled Systems.................................................................... 394
A7.2.6.1 Longitudinal (Tensile) Modulus E11.............. 395
A7.2.6.2 Transversal (Tensile) Modulus E22. ............... 396
A7.2.6.3 Orientation Parameter X................................. 396
A7.3 Nielsen Modification of Halpin–Tsai Equations with
Respect to the Maximum Packing Fraction: Numerical
Illustration........................................................................................ 396
A7.3.1 Maximum Packing Functions......................................... 397
A7.3.2 Longitudinal (Tensile) Modulus E11............................... 398
A7.3.3 Transverse (Tensile) Modulus Ey.................................... 398
A7.3.4 Shear Modulus G.............................................................. 398
A7.4 Mori–Tanaka’s Average Stress Concept: Tandon–Weng
Expressions for Randomly Distributed Ellipsoidal
(Fiber-Like) Particles: Numerical Illustration............................. 399
A7.4.1 Eshelby’s Tensor (Depending on Matrix Poisson’s
Ratio and Fibers Aspect Ratio Only).............................. 399
A7.4.2 Materials’ Constants (i.e., Not Depending on Fiber
Volume Fraction)...............................................................400
A7.4.3 Materials and Volume Fraction Depending
Constants............................................................................ 401
A7.4.4 Calculating the Longitudinal
(Tensile) Modulus E11. ...................................................... 402
A7.4.5 Calculating the Transverse (Tensile) Modulus E22....... 402
A7.4.6 Calculating the (In-Plane) Shear Modulus G12............. 403
A7.4.7 Calculating the (Out-Plane) Shear Modulus G23..........404
A7.4.8 Comparing with Experimental Data.............................404
A7.4.9 Tandon–Weng Expressions for Randomly
Distributed Spherical Particles:
Numerical illustration...................................................... 406
A7.4.9.1 Eshelby’s Tensor (Depending on Matrix
Poisson’s Ratio Only)....................................... 406
A7.4.9.2 Materials’ Constants (i.e., Not
Depending on Filler Volume Fraction)......... 406
A7.4.9.3 Materials and Volume Fraction
Depending Constants..................................... 407
A7.4.9.4 Calculating the Tensile Modulus E...............408
A7.4.9.5 Calculating the Shear Modulus G.................408
A7.5 Shear Lag Model: Numerical illustration.................................... 409

Index........................................................................................................... 411
Preface

This book is an outgrowth of a course I have taught for several years to


master and doctorate students in polymer science and engineering at the
Université Pierre et Marie Curie (Paris, France). It is also based on around 30
years of interest, research and engineering activities in the fascinating field
of so-called complex polymer systems, i.e., heterogeneous polymer based
materials with strong interactions between phases. Obviously, rubber com-
pounds and filled thermoplastics belong to such systems. If one considers
that, worldwide, around 40% of all thermoplastics and 90% of elastomers
are used as more or less complicated formulations with so-called fillers, it
­follows that approximately 100 million tons/year of polymers are indeed
“filled systems.” Quite a number of highly sophisticated applications of
polymers would simply be impossible without the enhancement of some of
their properties imparted by the addition of fine mineral particles or by short
fibers, of synthetic or natural origin.
The idea that, if a single available material cannot fulfill a set of desired
properties, then a mixture or a compound of that material with another one
might be satisfactory is likely as old as mankind. Adobe, likely the oldest
building material, is made by blending sand, clay, water and some kind of
fibrous material like straw or sticks, then molding the mixture into bricks
and drying in the sun. It is surely one of the oldest examples of reinforce-
ment of a “plastic” material, moist clay, with natural fibers that was already
in use in the Late Bronze Age, nearly everywhere in the Middle East, North
Africa, South Europe and southwestern North America. In a sense, the basic
principle of reinforcement, i.e., to have a stiffer dispersed material to sup-
port the load transmitted by a softer matrix, is already in the adobe brick.
Therefore, the “discovery” of natural rubber reinforcement by fine powdered
materials, namely carbon black, in the dawn of the twentieth century surely
proceeded from the same idea.
At first, mixing rubber and carbon black was pragmatic engineering, it
gave a better and useful set of properties, and the technique could be some-
what mastered, thanks to side developments, such as the internal mixer. The
very reasons for the reinforcing effect remained unclear for a long time and
the question only started to be seriously considered by the mid ­t wentieth
century. Today, some light has been shed on certain aspects of polymer rein-
forcement, as will be reviewed through the book. But the story is surely
not complete because any progress in the field is strongly connected with
either the availability of appropriate experimental and observation tech-
niques or theoretical views about polymer–filler interactions, or (and most
likely) both.

xi
xii Preface

One of the starting points of my deep interest for filled polymers is the
simple observation that, whilst having different chemical natures, a num-
ber of filled polymers, either thermoplastics or vulcanizable rubbers, exhibit
common singular properties. This aspect will be thoroughly documented
throughout the book but a few basic observations are worth highlighting
here. Let us consider for instance the flow properties of systems that are as
(chemically) different as a compound of high cis-1,4 polybutadiene with a suf-
ficient level of carbon black and a mixture of polyamide 66 with short glass
fibers. They share the same progressive disappearance with increasing filler
content of the low strain (or rate) linear viscoelastic behavior. Regarding the
mechanical properties, the effect of either fine precipitated calcium carbon-
ate particles or short glass fibers on the tensile and flexural moduli of poly-
propylene are qualitatively similar but by no means corresponding to mere
hydrodynamic effects. So, many filled polymer systems are similar in certain
aspects and different in others. Understanding why is likely to be the source
of promising scientific and engineering developments.
The possibilities offered by combining one (or several) polymer(s) with one
(or several) foreign stiffer component(s) are infinite and the just emerging
nanocomposites science is an expected development of the science and tech-
nology of filled polymers, once the basic relationships between reinforce-
ment and particle size had been established. For reasons that are given in
Chapter 1, nanofillers have been excluded from the topics covered by the
book, whose objectives are to survey quite a complex field but by no means
offer the whole story.
As stated above, teaching the subject is the origin of the book. In my expe-
rience, nothing must be left in the shadow when teaching a complex sub-
ject and all theories and equations found in the literature must be carefully
checked and weighed, particularly if engineering applications are foreseen.
I am not a theoretician but an experimentalist with an avid interest for any
fundamental approach that might help me to understand what I am measur-
ing. Therefore, whilst theoretical considerations that lead to proposals such
as “property X is proportional to (or a function of) parameter Y,” i.e., X∝ Y or
X∝ F(Y), may be acceptable in term of (scientific) common sense, they are of
very little use for the engineer (and less so for the student) if the coefficient of
proportionality (or the function) is not explicitly given. This is the reason why
all equations displayed in the book have been carefully tested, using (com-
mercial) calculation software. When one loads theoretical equations with
parameters expressed in the appropriate units, then either the unit system
is inconsistent and the software gives no results because the unit equation
is considered, or the right units are used and the results of the theory can be
weighed, at least in terms of “magnitude order.” If the results have the right
order of magnitude, then the theoretical considerations are likely acceptable.
If not… Such an exercise is always useful and I am grateful to my editor
for having accepted, as appendices, a selection of calculation worksheets
(obviously inactive in a printed book) that offer numerical illustrations of
Preface xiii

several of the theoretical considerations discussed in the book. Readers who


are familiar with the calculation software I use will have no difficulties in
implementing these appendices in their own work.
As a last word, it is worth noting that writing a science book on an active
field is (by essence) a never ending task since new interesting contributions
are published every day. But working with an editor forces the scientist-
writer to accept a deadline, in other words to make choices, to develop more
certain subjects and drop other ones, and eventually to bring an end point,
not final but temporary as always in science and industrial applications.

Jean L. Leblanc
Bois-Seigneur-Isaac
Author Bio

Born in 1946, Jean L. Leblanc studied


­physico-chemistry at the University of
Liège, Belgium, with a special emphasis
on polymer science and received his PhD
in 1976, with a thesis on the rheological
properties on SBS bloc copolymers. He then
joined Monsanto Company where, from
1976 to 1987, he held various positions in
the rubber chemicals, the Acrylonitrile-
Butadiene-Styrene plastics (ABS), and the
santoprene• divisions. He left Monsanto in
1987 to join the italian company Montedison
as manager, technical assistance and
applied research, then moved to the position of manager applied research
when Enichem took over Montedison in 1989. In 1988, he became fellow of
the Plastics and Rubber Institute (U.K.) and in 1993 he qualified as European
Chemist (EurChem). In 1993, he was elected Professeur des Universités in France
and joined the Université Pierre et Marie Curie (Paris, France), as head of the
then newly developed polymer rheology and processing laboratory, in col-
laboration with the French Rubber Institute. He is still in this position today
and, since 1997, also teaches polymer rheology and processing at the Free
University of Brussels (Belgium), as a visiting professor. He has written two
books and more than 100 papers.

xv
1
Introduction

1.1 Scope of the Book


This book deals with the properties of filled polymers, i.e. mixtures of
­macromolecular materials with finely divided substances, with respect to
established scientific aspects and industrial developments. So-called (poly-
mer) composites, that consist of long fibers impregnated with resins, such as
glass fibers reinforced polyesters or carbon fibers reinforced epoxy resins, are
not within the subject of this book. Filled polymers discussed hereafter are
heterogeneous systems such that, during processing operations, the polymer
and the dispersed filler flow together. In other words, filled ­polymers are
macroscopically coherent masses that exhibit interesting physical, mechani-
cal, and/or rheological properties, often peculiar, but always resulting from
interactions taking place between a matrix (the polymer) and a dispersed
phase (the filler). It follows obviously that filled polymers have to be prepared
through mixing operations, generally complex and requiring appropriate
machines, in such a manner that a thorough dispersion of filler particles is
achieved.
Why does one prepare filled polymers? There are many reasons, all of
them related to engineering needs. Generally one mixes fillers into polymers
in order to modify properties of the latter, either physical properties, such
as density or conductivity, or mechanical properties, for instance modu-
lus, stiffness, etc., or rheological properties, i.e., viscosity or viscoelasticity.
Occasionally, fillers are also used for economical reasons, as cheap additives
that reduce material costs in polymer applications. Table 1.1 gives the relative
volume costs of a few common mineral fillers in comparison with several
polymers, using polypropylene (PP) as a reference. Clearly, only grinded cal-
cium carbonate and finely divided clays can be considered as “economical”
fillers; in all other cases, specific property improvements are sought when
mixing the filler and the polymer.
A few numbers allow underlining the economical importance of filled poly-
mers. According to recently published market research reports (2007), the
worldwide consumption of fillers is more than 50 million tons with a global
value of approximately €25 billion. Many application areas are concerned,

1
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254 state animal

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291 and

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