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All polymeric slurries that have a high concentration of filler are shear thinning. Shear thinning is an important characteristic of polymers, filled and unfilled, because it enables an increase in the throughput, shear rate in a die or an injection molding system without having to use substantially more power to increase the flow rate. Newtonian fluid-based slurries show an increase in shear thinning as the concentration of “filler” increases above the percolation threshold. As particle maximum packing concentration is approached the slurries begin to approach a perfect pseudoplastic fluid. In some cases, the shear thinning characteristics of a filled polymer do not increase substantially as the filler loading is increased. This is a quite different response than in Newtonian fluid-based slurry. Therefore, it is important to understand the materials engineering interactions that control shear thinning so that process flow models can better predict the performance of filled polymer systems. Highly filled polymers can have processing issues, including high screw shaft torque, energy consumption, die pressure and melt temperature rise. Previous theoretical developments and experimental evaluations of highly filled polymer melts showed that the rheology can be effectively described with a percolation model. In this work, capillary rheometer measurements using several low-density polyethylene resins, calcium carbonate and titanium dioxide fillers are reported using percolation theory concepts. The theoretical treatment of the rheology as a particulate percolating system with power-law behavior is used to analyze capillary rheometer data. The observed effects of resin molecular weight, filler type and size on rheology are described. Engineers that design and debottleneck polymer processes need to utilize the polymer viscosity at the minimum process shear rate to determine the smallest motor that will allow the process to run; in addition, the shear thinning characteristics of the polymer are used to indicate how much increased production may be possible with a given motor size. Thus, some examples of expected effects on melt processing are also presented.

Investigation of the Effect of Filler Concentration on the Flow Characteristics of Filled Polyethylene Melts