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The dispersion behavior of particles added to polymeric materials in an oval-type mixer was investigated; to examine how the material quality correlates with two processes: 1) all material passes through the tip region of the rotor at least once during mixing, 2) irregular flow behavior in the initial period of mixing disappears. Irregular flow had been analyzed in previous studies in relation to a "breaking phenomenon" in which all of the highly viscous and undispersed material remaining on the rotor surface suddenly breaks and flows out through the tip region of the rotor. Also optimum mechanical dimensions for an oval rotor were evaluated by studying these effects. The dispersion levels for carbon black added to low-density polyethylene were measured under various mixing conditions in an ovaltype twin-rotor mixer. A critical point was discovered in the relationship between dispersion level and specific energy charged to the material; there the energy efficiency drops suddenly. The total number of rotor revolutions required to reach this critical point was compared with that for the "breaking phenomenon". The latter was calculated by estimating the passing rate of remaining material through the tip region of the rotor. Both numbers were in close agreement. An optimum tip clearance for dispersion of added particles was then calculated by maximizing a dipersion parameter, which indicates the energy charged to the remaining material passing through the rotor tip region. Subsequent experimental results confirmed the calculations. From these analyses, a scale-up rule for optimum tip clearance was developed.

Analysis of Irregular Dispersion of Carbon Black into Polymeric Material in an Oval Type Mixer