Experimental Study on Factors Influencing Throughput Rate and Process of Polymer-Mineral Filler Mixing in a Twin Screw Extruder

The experimental study of mixing polymer (polypropylene, PP) with mineral filler (Talc) by both simultaneous and separate feed system in a twin screw extruder was described. In this study, melt flow rate (MFR) of PP, talc particle size and talc mixing ratio to PP were selected as parameters of interest. It was found that these parameters had influences on the maximum throughput rate of mixture. In the cases of constant talc particle size and mixing ratio while MFR of PP was varied from 1.8 to 33, it was observed that throughput rates of all mixtures with different MFR values increased as a function of screw speeds. Throughput rates of the mixture of lower MFR PP (MFR = 1.8) were slightly lower than those of the higher MFR mixture (MFR = 10, 33) for both simultaneous and separate feed systems. With regard to effects of talc particle size, compounds having fixed talc mixing ratio showed lower throughput rates when talc particle size was smaller. In the case where talc mixing ratio was varied, compounds with fixed MFR of PP and talc particle size showed lower throughput rates when talc mixing ratio was larger. The mixing state in the mixing zone was also observed. Based on the overall findings, the mechanisms of filler mixing were clearly understood. The observed mixing patterns were similar for both simultaneous and separate feed systems. It was found that the elimination of the air accompanying the filler when the filled polymer mixture passed down the extruder is important for mixing. Through the experimental observations, the schematic diagram, the model and the flow chart of the proper filler mixing process were proposed.