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JULY2010

CRB 30503 POLYMER ADDITIVES & BLENDS


Polymer, UniKL
1
Chapter 2
UniKL MICET
Fillers and Fibers
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
2
Topic Outcomes
It is expected that students will be able
to:
Describe the types of fillers and fibers.
Explain the similarities and differences
between fillers and fibers.
Explain the theory of the action of
fillers and reinforcements.
Discuss the current developments in
fillers and fibers technology.
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CRB 30503 POLYMER ADDITIVES & BLENDS
3
What are the definitions of fillers,
and fibers?

What are the functions of fillers
and fibers?

What are the differences between
fillers and fibers?
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
4
What are the differences between
extender filler and reinforcing filler?

How they act as functional fillers to
improve the mechanical properties?

What are the types of fillers and
fibers?
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
..as solid additives
incorporated (fill space) into plastic
matrix
alter, increase or improve bulk properties
2 categories:
inert or extender filler (cost reduction)
Reinforcing fillers (mechanical
properties)
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Polymer
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..mainly, cost reduction
volume/ density increase
reduce plastics
..affect other properties, as well
eg: talc (a fine-grained white, greenish, or gray mineral,
Mg
3
Si
4
O
10
(OH)
2
) ~ density h, shrinkage i,
hardness h, heat deflection temp. h

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Inert or extender fillers
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..improve the properties via several
mechanisms.
eg: a chemical bond is formed between the
filler and the polymer
eg: the volume occupied by the filler affects
the properties of the thermoplastics
..due to the surface properties and
interaction between the filler and the matrix
(i.e good interfacial bonding)
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Reinforcing fillers
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Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
.. good interfacial bonding depends on:
Particle shape
platelike or fibrous particles may be
oriented during processing resulted in
anisotropic properties.
Particle size
smaller, higher mechanical property (tensile)
Bigger, reduced properties vs pure
thermoplastic
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..cont.
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
.. good interfacial bonding depends on:
Distribution of sizes
Good distribution results in increase in
mechanical properties.
Surface chemistry of the particle
To promote interaction with polymer for
good a interfacial adhesion.
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..cont.
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Classification of Fillers
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Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Shapes of Fibers and Fillers
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CRB 30503 POLYMER ADDITIVES & BLENDS
Shapes of Fibers and Fillers
JULY2010
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CRB 30503 POLYMER ADDITIVES & BLENDS
..Is the ratio of length to width of filler
particles.
Flakes or fibers ~ have aspect ratios that make them
resist movement or realignment thus improving
strength.
Spheres have no aspect ratio and produce composites
with isotropic

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ASPECT RATIO
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CRB 30503 POLYMER ADDITIVES & BLENDS
Shapes of Fibers ~ strength mechanism
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CRB 30503 POLYMER ADDITIVES & BLENDS
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..cont.
Spherical Lamellar* Fibrous
Sand Mica Glass fibers
Quartz powder Talc Asbestos
Silica Graphite Wollastonite
Glass spheres Kaolin Carbon fibers
Calcium carbonate Cellulose
Carbon black Synthetic fibers
Metallic oxides
*Lamella is a term for a platelike/platelet structure, appearing in multiples
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
.. Fillers can be classified by size, 2 group:
Nano-scale materials
Large scale materials)

Nanocomposite (..new development Nano Technology)
..are submicron in size (<1x10
-9
m)
..late 1980s, first developed mostly in nylon
..1990s, limited application in nylon & other engineering plastics
..late 1990s, application in commodity plastics (polyolefins)
..2002, commercial automotive application General Motors
..if uniformly spread out, 5g could cover the surface of footfield
..well dispersed, 2.5% has properties of 20% talc filled!
..advantages: low thermal expansion, lighter weight, reduced
flammability and improved physical properties.
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..cont.
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Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Function The basic purpose is to 'fill' a compound (increase
bulk at low cost). To do this the mix must be
homogeneous, with good filler/polymer adhesion, and
the filler also begins to improve mechanical
properties.
Most particulate fillers have a higher specific gravity
than polymers, but some have been developed that
can reduce the weight of the compound.
Geometry and surface texture fundamentally
influence adhesion properties: these can be improved
by surface treatment.
Properties Stiffness, hardness, shrinkage/dimensional stability:
thermal stability and flame retardancy may also be
improved.
FILLERS At a Glance
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Materials/
characteristics
Clays, calcium carbonates, talc, silicates. Pigments
such as titanium dioxide and carbon black may also
have a reinforcing effect. Glass or ceramic micro
spheres can also offer good properties.


Disadvantages Compounding may present problems, but surface
treatments and dispersing agents will help. Solid
mineral fillers add to weight.

New
developments
Improved surface treatments for better
dispersability, multi-functions, lightweight fillers;
nano-composites.

FILLERS At a Glance (cont)
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Type Characteristic/main application
Alumina trihydrate Extender: serving as flame retardant and smoke
suppressant
Barium sulphate Filler and white pigment: increases specific
gravity, frictional resistance chemical resistance
Calcium carbonate Most widely used extender/pigment or filler for
plastics
Calcium sulphate Extender: also enhances physical properties,
increases impact, tensile, and compressive
strengths
Common fillers and reinforcements for plastics (cont)
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Type Characteristic/main application
Carbon black Filler: used as pigment and anti-static agent,
or as an aid in cross-linking; electrically
conductive
Carbon/graphite
fibres
Reinforcement: high modulus and strength;
low density, coefficient of expansion,
coefficient of friction: conductive
Feldspar,
nepheline syenite
Speciality filler: easily wetted and dispersed:
gives transparency/translucency; resistant to
chemicals and weathering
Glass fibre Largest volume reinforcement: giving high
strength, dimensional stability, heat
resistance, chemical resistance
Common fillers and reinforcements for plastics (cont)
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Type Characteristic/main application
Kaolin Second-largest extender/pigment by volume: mainly
used in wire and cable, PVC flooring, SMC/BMC
Metal fillers,
filaments
Electrical and/or thermal conductivity or magnetic
properties; reduce friction: expensive
Mica Flake-form reinforcement: improves dielectric, thermal,
and mechanical properties; low in cost

Microspheres
(hollow)
Reduced weight; improved stiffness and impact
resistance
Microspheres
(solid)
Improved flow properties and stress distribution

Common fillers and reinforcements for plastics (cont)
JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Type Characteristic/main application
Organic fillers Extenders/fillers (wood flour, nutshell, corncobs, rice,
peanut hulls)
Polymeric fillers lightweight
Silica Filler/extender/reinforcement: makes more thixotropic,
aiding plate-out in PVC; acts as flatting agent

Talc Filler/extender/reinforcement: improves stiffness,
tensile strength, resistance to creep
Wollastonite Improves strength, reduces moisture absorption,
higher heat/dimensional stability, improved electrical
properties: high loadings possible
Common fillers and reinforcements for plastics (cont)
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
..do not dissolve in the polymer matrix
fillers vs fibers:
..fillers are small particles and contribute only
slightly to strength
..fibers to produce dramatic improvements in
physical properties (strength, impact &
stiffness)
..but some materials can act as filler or fiber
or both (eg: glass)
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Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Interface bond between matrix and
reinforcements
Properties of the reinforcement
Size and shape of the reinforcement
Loading of the reinforcement
Processing technique
Alignment or distribution of the
reinforcement
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JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
1. Interface bond between matrix and
reinforcement
The matrix function to transfer most of the
stress to the reinforcement.
..so there must be an excellent adhesion
between the matrix and reinforcement.
2. Properties of the reinforcement
..vary & determine by composition, shape,
size, production, handling, processing,
surface enhancement & no of defects.
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..cont.
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CRB 30503 POLYMER ADDITIVES & BLENDS
3. Size and shape of the reinforcement
..provide superior handling, loading,
processing, packing orientation or adhesion
in the matrix.
..some fibers are so small & handle by
bundles, others are woven in cloth.
..particulates are more likely to be randomly
distributed than long fibers.
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..cont.
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
4. Loading of the reinforcement
..mechanical strength depends on the amount
of reinforcing agent it contains.
..eg: 60% reinforcement with 10% resin gives
6 times stronger than a part containing
opposite amounts of these two materials.
..some glass filament-wound composites may
have up to 80% (by wt.) loading by
unidirectional orientation of the filament
..most reinforced TP composites contain less
than 40% (by wt.) reinforcements.
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..cont.
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CRB 30503 POLYMER ADDITIVES & BLENDS
5. Processing technique
..some technique allow the fibers to be more
carefully aligned or oriented.
..during processing, fibers may be broken or
damaged resulting in lower mechanical
properties.
..particulates & short fibers are more likely
to have random rather than oriented
placement in the matrix.
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..cont.
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CRB 30503 POLYMER ADDITIVES & BLENDS
6. Alignment or distribution of the
reinforcement
..allows versatility in composites.
..the processor can align or orient the fibers
to provide directional properties (eg:
filament winding process ~ fishing rod).
..parallel (anisotropic/continuous strands)
alignment > bidirectional alignment (cloth) >
random (mat) alignment in term of strength
property.
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..cont.
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Glass
Carbonaceous (eg. Carbon, graphite)
Polymer (eg. Kevlar, cellulose acetate)
Inorganic (eg. Aluminium oxide, MgO
3
)
Metal (eg. Steel, aluminium)

JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Lamina
..basic structural element of laminar
composite is the lamina
fibrous, six sub-classes..
Glass
Carbonaceous
Polymer
Inorganic
Metal
hybrids
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JULY2010
Polymer
UniKL
CRB 30503 POLYMER ADDITIVES & BLENDS
Lamina
..a thin plate, sheet or layer (Polymer
Dictionary)
..consist of unidirectional fibers, woven
cloth, or sheets of material.
Individual layer act as reinforcement..
Performance depends on lamina selection,
alignment and composition.
eg: random-chopped strand mat gives equal
strength properties in all direction.
eg: unidirectional fiber alignment has the
highest strength parallel to the fiber.
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JULY2010
Polymer
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Fibrous, six sub-classes..
Glass
Carbonaceous
Polymer
Inorganic
Metal
hybrids
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Glass fibers
..most important reinforcing materials
..replacing metal parts due to better
strength & light weight.
How it produced? ..involves pulling a strand
of molten glass tru small orifice, diameter
controlled by pulling action.
Glass is from silica, few types:
Type E ~ good electrical properties..
Type C ~ chemical resistance.
Type D ~ low dielectric constant/low density.
Type I ~ contains lead oxide for radiation
protection.
Type S ~ for high-strength uses.
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JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Glass fiberstypes & forms:
Rovings ~ long strands, loosely associated
rope
Chopped fibers ~ chopped strands from
rovings; length size 3~50mm (0.125~2in)
Milled fibers ~ length size < 1.5mm,
produced by hammer milling glass strands,
add to premix to increase viscosity &
product strength.
Yarn ~ resemble rovings but twisted like a
rope, for large container.
Woven cloth ~ for thick reinforcement.
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Carbonaceous fibers
..made by oxidizing, carbonizing & graphitizing
an organic fiber like rayon & polyacrylonitrile
(PAN).
Rayon is natural based material made from
cellulose of wood pulp or cotton.
PAN is a resinous, fibrous, or rubbery organic
polymer, chemically modified to make the carbon
fibers found in tennis and badminton rackets, high-
tech bicycles, blades for turbine & helicopter.
Graphite fibers exceed glass strength, used as
self-lubricating materials.
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Reinforcementcont
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Polymer fibers
..are used as reinforcements in belting, ties
gears, etc.
eg: polyester, polyamide, polyvinyl acetate
(PVA) cellulose acetate (CA), etc.
eg: Kevlar aramid (DuPont trademark), gives
twice stiffness & half density of glass.
Applications ~ mostly in composite! ..with high
strength polymer matrix such as epoxy resin,
polyester, phenolic etc.
eg: polyester & polyamide fibers use in bulk
molding compound, sheet molding compound,
layup, pultrusion, filament winding
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Reinforcementcont
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
DuPont Kevlar pulps are highly fibrillated chopped
fibers that can be used as specialty additives to enhance
performance by providing excellent reinforcement and
viscosity control under shear stress. Kevlar pulp is used in
automotive brake pads, gaskets, automatic transmission
papers, and as a viscosity control additive for adhesives
and sealants.

Properties
Description Highly fibrillated, short (0.5-1mm) fibers
Color Yellow
Useful temperature range -200 to +350C
Specific gravity 1.45
Specific surface area 7-11m/g
Bulk density 3-7 lbs/ft
JULY2010
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NEW Kevlar XP fabric technology

This patented technology provides approximately 15%
reduction in backface deformation and superior ballistic
performance in a 100% Kevlar solution. Kevlar XP
allows more comfortable vest design with at least 10%
reduction in overall weight.
JULY2010
Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Kevlar thread helps make
fire-resistant (FR) mattresses
more effective by improving
the integrity of the seams
between panels of flame
resistant material
High strength, light weight and
thermal stability have made
Kevlar paper a crucial building
material for honeycomb cores in
the aerospace industry, where it
is used in parts such as cabin
floors, rotor blades and engine
nacelles
Kevlar paper for aerospace applications
Kevlar in fire resistance mattresses
JULY2010
Polymer
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Gloves and protective
clothing made from
Kevlar yarn provide
superior cut, abrasion and
thermal resistance for
people who work with
glass, sheet metal and
other hazardous objects
Kevlar yarn
Kevlar helps protect law
enforcement, corrections and
military personnel from death or
serious injury with an ever-growing
line of products designed to help
defend against ballistic projectiles,
fragmentation and puncture-
producing handheld weapons.
Kevlar protection products
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Polymer fiberscont
eg: polyester & polyamide fibers use in;
bulk molding compound (BMC)
sheet molding compound (SMC)
layup
pultrusion
filament winding
resin transfer molding (RTM)
reinforced reaction injection molding (RRIM)
thermal expansion resin transfer molding (TERTM)
injection molding operations
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Reinforcementcont
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Inorganic fibers
..a class of crystalline fibers.
..made from aluminum oxide, magnesium oxide,
potassium titanate, silicon carbide, titanium
boride etc.
eg: boron fibers is used to make many
composite parts for military and civilian aircraft
Very costly with high tensile strength > 40 GPa
Special use in dental plastics fillings, turbine
compressor blades, special deep water
equipments etc.
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Reinforcementcont
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Polymer
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CRB 30503 POLYMER ADDITIVES & BLENDS
Metal fibers
..continuous filaments from steel, aluminum etc.
Used for added strength, heat transfer, and
electrical conductivity.

Hybrid fibers
..two or more fibers are combined
(hybridization) to tailor the reinforcement to
needs of the designer.
eg: glass & carbon fibers are used together to
increase impact strength & toughness, reduce
cost (i.e not 100% carbon fiber)
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Reinforcementcont
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CRB 30503 POLYMER ADDITIVES & BLENDS
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Overview of wide
variety of composite
parts used in the Air
Forces C-17
transport. It uses
15000 lb of advanced
composites
..think about it!
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..in general
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NATURAL FIBERS
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The flax plant (Linum usitatissimum) is the source of two
products: flaxseed for linseed oil and fiber for linen
products. Plants with two distinct types of growth are
used for seed and fiber production.
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Hemp (Cannabis sativa)
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Jute is a long, soft, shiny
vegetable fiber that can be
spun into coarse, strong
threads. It is produced from
plants in the genus
Corchorus, family Tiliaceae.
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Sisal (Agave sisalana) is an agave that yields a stiff
fiber traditionally used in making twine, rope and also
dartboards.
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The main uses of kenaf fiber have been rope, twine,
coarse cloth (similar to that made from jute), and paper. In
California, Texas and Louisiana, 3,200 acres (13 km) of
kenaf were grown in 1992, most of which was used for
animal bedding and feed.
Uses of kenaf fibre include engineered wood, insulation,
and clothing-grade cloth.

Panasonic has set up a plant in Malaysia to manufacture
kenaf fibre boards and export them to Japan, oil and
liquid absorbent material, soil-less potting mixes, animal
bedding, packing material, cut bast fiber for blending with
resins for plastic composites, as a drilling fluid loss
preventative for oil drilling muds, for a seeded hydromulch
for erosion control and various types of erosion and
environmental mats, such as seeded grass mats for
instant lawns and moldable mats for manufactured parts
and containers Hemp (Cannabis sativa)
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Coir ~ The fiber obtained
from the husk of a
coconut, used chiefly in
making rope and matting
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