CARBON BLACK MAGIC

TURNING ELECTRICALLY CONDUCTIVE

PLASTICS INTO PRODUCTS
This is the first installment in a series of articles
on the processing of Premix’s electrically conductive
plastics. The series kicks off with a look at the key
element of conductive compounds – carbon black – and
how it is used for creating the perfect compound mix.

Low structure High structure

Carbon black magic
Conductive carbon black is the most
reliable and cost-efficient choice for
producing electrically conductive plas-
tic compounds. The secret behind the
perfect carbon black compound lies in
three important factors:
• Selecting the optimal carbon
black type for the purpose;
• Formulating the compound;
• Optimizing the compounding
technique.
Electrically conductive plastics are
used in countless processing methods
and final applications. The role of the
compounder is to ensure that above
factors are executed correctly and to
help the customer take full advantage
of the compound in the manufactur-
ing process. Together, these measures
guarantee that the desired goals for
the end products are met successfully.
Step 1: Picking the right carbon black
Carbon black comes in many differ-
ent varieties. The carbon black that
works perfectly in truck tires is not the
right choice for conductive compounds.
Selecting the carbon black with just the
right features is the first important step
towards a successful end product.
The most important factor affecting
the electrical performance of carbon
black is its structure. Particle size and
porosity also have an impact on the
electrical behavior of the electrically
conductive compound.
Factors that improve electrical
conductivity:
• High structure: high structure means
that the carbon black agglomerates
form long and branched chains. Such
a structure is ideal for conductive
compounds – the required conductivity
can be reached with lower loading levels.
• Small particle size: smaller size means
higher electrical conductivity. If the
particles are small and relatively
uniform in shape, their surface
area is larger than otherwise. Extra
conductive carbon blacks, with the
smallest particle size, provide the
highest electrical conductivity.
• High porosity: higher particle porosity
enables better electrical conductivity.
Step 2: Formulating the right mix
After exceeding a certain loading level,
carbon black changes the electrically
insulating base polymer into electri-
cally conductive plastic. The decrease
in electrical volume resistivity due to
the increased amount of carbon black
can be described using a percolation
model. The percolation behavior of car-
bon black depends on the qualities men-
tioned in step 1: particle size, structure
and porosity.
Premix’s R&D specialists can select
just the optimum carbon black load
needed to achieve the required elec-
trical properties. Finding the correct
loading level is extremely important: too
high a carbon black load has a negative
impact on the compound’s mechanical
properties. It also increases viscosity,
causing problems in the injection mold-
ing process, for example.
The percolation curve illustrates the
relationship between the quantity of

Choosing the right carbon
black also depends
on how the material
will be processed.
added carbon black (CB load) and the
achieved electrical resistivity. Note the
narrow threshold in which the electri-
cal resistivity dramatically drops. After
this threshold level, increasing carbon
black will no longer improve the electri-
cal properties.
Usually the steepest part of the
curve hits the static dissipative resis-
tance levels (106–109ohms). This makes
the development and production of dis-
sipative carbon black compounds very
challenging. The carbon black content
and the production process require
careful control and monitoring.
Choosing the right carbon black also
depends on how the material will be pro-
cessed. For example, during the injec-
tion molding process, the compound is
subjected to different processing condi-
tions than during the extrusion process.
For each process, roughly speaking,
there is a matching type of carbon black.
Premix has accumulated 30 years of
expertise in formulating and manufactur-
ing electrically conductive compounds.
Based on our research, experience and
years of product development, we have
found the perfect mix for any requirement.
Step 3: Optimized
compounding process
The final piece of the puzzle for creating
a perfect electrically conductive com-
pound is finding the optimal technique
for dispersing the carbon black to the
base polymer.
The Premix compounding lines have
been optimized for the production of
electrically conductive plastics. For
each formulation and base polymer, our
processing engineers select the right
machinery with optimal screw geometry
and granulation technology.
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Primary particles
size: ~0,01 microns
Aggregate
size: ~0,1-0,5 microns
strong bonds between
primary particles
Agglomerate
size: >1 mm
weak bonds between
aggregates
Carefully defined processing param-
eters ensure that the shear forces and
process temperatures are at the ideal
level. In optimal conditions, the carbon
black agglomerates are separated into
aggregates which are then dispersed
and distributed evenly within the com-
pound. This is done without breaking
the carbon black’s structure.
Continuous quality control throughout
the process and seamless cooperation
between the production and quality assur-
ance departments are the final check-
points on the way to the perfect outcome.
Next up: processing and
measuring electrical properties
The following articles in this series will
focus on the guidelines for processing
compounds in injection molding and
extrusion applications. We will also pro-
vide practical insights into resistivity
measurements.
We would love to hear your feedback,
questions and comments on this article.
Please send your ideas to
presearch@premixgroup.com!