Filler (materials)

Fillers have been used by the plastics industry since its inception. It was the discovery that wood flour
made it possible to mould the liquid resin phenol formaldehyde that effectively launched the industry at
the beginning of the twentieth century, and subsequently PVC has proved a major user of fillers. In the
intervening years, however, the use of fillers for plastics has changed significantly. While the original,
basic low-performance materials such as clays and chalks are still used very widely, the modern market
is placing increasing pressure on manufacturers to offer fillers that give some additional value, such as
improvement in mechanical properties. They are increasingly called upon to provide other value-added
functions, such as mechanical properties, UV or heat stability, thermal or electrical conductivity,
dimensional stability, or flame retardancy. Increased interest in environmental aspects is creating
demand now for fillers that are based on vegetable materials such as cellulose. The potential offered by
a filler is determined essentially by its chemistry, and especially by its physical aspects, such as the size
and geometry, surface area, and surface energy of its particles. Nevertheless, the weight of the filler
remains important. Some fillers (such as barytes) are especially selected for their heavy weight, giving
the compound an improvement in acoustic-deadening properties. There is also considerable interest
also in fillers that are lightweight, such as hollow particles, usually ceramic or glass microspheres.

Filler materials are particles added to resin or binders ( plastics, composites, concrete)

that can improve specific properties, make the product cheaper, or a mixture of
both.[1] The two largest segments for filler material use is elastomers and plastics.
[2]
 Worldwide, more than 53 million tons of fillers (with a total sum of
approximately US$18 billion) are used every year in application areas such
as paper, plastics, rubber, paints, coatings, adhesives, and sealants. As such, fillers,
produced by more than 700 companies, rank among the world's major raw
materials and are contained in a variety of goods for daily consumer needs. The
top filler materials used are ground calcium carbonate (GCC), precipitated calcium
carbonate (PCC), kaolin, talc, and carbon black. [3] Filler materials can affect the
tensile strength, toughness, heat resistance, color, clarity etc. A good example of
this is the addition of talc to polypropylene.[4] Most of the filler materials used in
plastics are mineral or glass based filler materials. [4] Particulates and fibers are the
main subgroups of filler materials. Particulates are small particles of filler which
are mixed in the matrix where size and aspect ratio are important. Fibers are small
circular strands that can be very long and have very high aspect ratios. [5]

Contents

 1 Types

o 1.1 Calcium carbonate (CaCO3)

o 1.2 Kaolin

o 1.3 Magnesium hydroxide (talc)

o 1.4 Wollastonite (CaSiO3)

o 1.5 Glass

o 1.6 Fly ashes

o 1.7 Nanofillers

o 1.8 Polymer foam beads

o 1.9 Masonry filler

o 1.10 Other fillers

 2 Mechanical properties

o 2.1 Tensile strength

o 2.2 Elastic modulus

o 2.3 Impact resistance (toughness)

o 2.4 Wear resistance

o 2.5 Fatigue resistance

o 2.6 Thermal deformation

o 2.7 Creep

 3 Weldability of plastic fillers

  4 Applications of filler in plastic industry

Calcium carbonate (CaCO3)[edit]

Referred to as "chalk" in the plastic industry, calcium carbonate is derived from

limestone and marble. It is used in many applications including PVC's and unsaturated
polyesters. As much as 90% CaCO3 can be used to make a composite. These additions
can improve molding productivity by decreasing cooling rate. They can also increase
operating temperatures of materials and provide insulation for electrical wiring. [6]

CaCO3 is used in filler masterbatch as a base with large percentage in composition.

Calcium carbonate powder accounts for 97% of composition will bring for
white/opaque products more whiteness. So manufacturers can reduce the usage of
white masterbatch. With smaller percent, calcium carbonate powder can be used for
color products. In addition, it brings for final plastic products more bright and glossy
surface.[7]

Kaolin[edit]

Kaolin is mainly used in plastics for its anti blocking characteristics as well as an infra
red absorber in laser marking.[6] It increases impact strength and heat resistance.
Metakolinite is used to stabilize PVC.[6] Kaolin has also been shown to increase the
abrasion resistance and can replace carbon black as a filler material and improve flow
properties of glass reinforced substances.[6]

Magnesium hydroxide (talc)[edit]

Block of talc.

Talc, a soft mineral and generally more expensive than calcium carbonate. It is

derived from layering sheets of magnesium hydroxide with silica. In the plastic
industry it is used for packaging and food application due to its long-term thermal
stability.[6][5]

Wollastonite (CaSiO3)[edit]

Wollastonite has an acicular structure with a relatively high specific gravity and high

hardness. This filler can improve moisture content, wear resistance, thermal stability,
and high dielectric strength. Wollastonite competes with platy filler substances like
mica and talc and also can be used to replace glass fibers when creating
thermoplastics and thermosets.[5]

Glass[edit]

Glass microsphere filler (left) and fiber fillers (right)

Glass filler materials come in a few diverse forms: glass beads, short glass fibers, long
glass fibers. in plastics by tonnage.[5] Glass fibers are used to increase the mechanical
properties of the thermoplastic or thermoset such as flexural modulus and tensile
strength, There is normally not an economic benefit for adding glass as a filler
material. Some disadvantages of having glass in the matrix include low surface
quality, high viscosity when melted, poor weldability and warpage.[5] The addition of
glass beads will help with oil absorption and chemical resistance. [6]

Fly ashes[edit]

Coal and shale oil fly ashes have been used as a filler for thermoplastics that could be
used for injection molding applications.[8]

Nanofillers[edit]

Nanofiller have a particle size less than 100 nanometres. They have a high aspect ratio
and are mainly used as scratch resistant and fire resistant fillers.[4] Nanofillers can be
broken out into three groups nanoplates, nanofibers, and nanoparticles. Nanoparticles
are more widely used than nanoplates and nanofibers but nanoplates are starting to
become more widely used. Nanoplates are like conventional platy fillers like talc and
mica except the thickness is much smaller. Advantages of adding nanofillers include
creating a gas barrier and their flame retardant properties. [5]

Polymer foam beads[edit]

Polymer Foam Beads can have a bulk density as low as 0.011 g/cc and range in size
from 45 microns to over 8 mm. Common drawbacks to using Polymer Foam Beads in
formulated systems include static, temperature and chemical resistance limitations and
difficulty achieving a homogenous blend within a formulated system due to their
extremely low bulk density. However, these limitations can be mostly if not entirely
overcome through the use of formulation modifications, additives and other surface
treatments. Despite these potential challenges, Polymer Foam Beads can be added to
formulated systems when weight or cost savings in a finished good are required.

Masonry filler[edit]

Masonry filler is used to repair cracks and holes in exterior walls, and is typically
made using cement and hydrated lime. Manufacturers include Toupret.[9]

filler materials include gravel, stone, sand, and rebar. Gravel, stone, and sand are
used to reduce the cost of concrete. Rebars are used to strengthen the concrete.
[10]

Table Of Filler Materials and Physical Properties [11]

Density Mean Size
Filler Type Mohs Hardness Aspect Ratio/Shape
(g/cm )
3
(Microns)
Calcium Carbonate 2.7 3-4 0.02-30 1-3 Blocky
Talc 2.7-2.8 1 0.5-20 5-40 Plate
Wollastonite 2.9 4.5 1-500 5-30 Fiber
Mica 2.8-2.9 2.5-4 5-1000 20-100 Plate
Kaolin 2.6 2 0.2-8 10-30 Plate
Silica (Precipitated) 1.9-2.1 5.5 0.005-0.1 ~1 Round
Carbon Black 1.7-1.9 2-3 0.014-0.25 ~1 Round
Dolomite 2.85 3.5-4 1-30 ~1 Round
Barium Sulfate 4.0-4.5 3-3.5 0.1-30 ~1 Round
ATH Al(OH)3 2.42 2.5-3 5-80 1-10 Plate
MDH Mg(OH)2 2.4 2.5-3 0.5-8 1-10 Plate
Diatomaceous earth 2-2.5 5.5-6 4-30 2-10 Disc
Magnetite/Hematite 5.2 5.5-6 1-50 ~1 Blocky
Halloysite 2.54 2.5 1-20 5-20 Tube
Zinc Oxide 5.6 4.5 0.05-10 1 Round
Titanium Dioxide 4.23 6 0.1-10 1 Round

Mechanical properties[edit]
Tensile strength[edit]

Tensile strength is the most used method to evaluate filler materials. The tensile
strength of the composite can be calculated using the equation

σc= σp(1-aΦbf +cΦfd)[12]
where

σc = tensile strength of composite

σp = tensile strength of polymer matrix
Φf = volume fraction of filler
a, b, c, d are constants depending on the type of filler. "a" relates to stress
concentration and is based on adhesion characteristics of the filler material. "b"
is normally 0.67. c and d are constants that are inversely related to particle size.
[12]

Elastic modulus[edit]

The elastic modulus (Young's modulus) of a filled polymer can be found using the

equation below:

E = E0 (1 + 2.5Φ + 14.1Φ2)[12]

where:

E0 = Modulus of unfilled resin or binder

Φ = Filler concentration

Polymers with smaller additions of filler follow this equation closely. In general
addition of filler materials will increase the modulus. The additions of calcium
carbonate and talc will increase the elastic modulus, while the addition of elastic filler
materials can reduce the value slightly. Filler materials increase the modulus due to
their rigidity or stiffness and good adhesion with the polymeric matrix. [12]

Impact resistance (toughness)[edit]

In general fillers will increase impact resistance. The contributing factors that improve
impact resistance is particle size, particle shape and particle rigidity. Fibers improve
impact resistance the most due to their large aspect ratio. Low hardness fillers will
decrease impact strength. Particle size, within a specific range can increase the impact
strengths based on the filler material.[12]

Wear resistance[edit]

The wear volume (Ws) for plastic materials can be calculated:

Ws = KμPDW/(EIs)[12]

where:

K = Proportionality constant
P = force
E = Modulus
D = Sliding distance
W = load
Is= Interlaminar shear strength

Matrix and filler both contribute to wear resistance. In general a filler is selected
to decrease the friction coefficient of the material. Particle size and shape are
contributing factors. Smaller particle size increase wear resistance because they
cause less debris. silica, alumina, molybdenum disulfide, and graphite powder
are common filleFatigue resistance[edit]

Filler can have a negative or positive effect on fatigue resistance depending on the

filler type and shape. In general fillers create small discontinuities in the matrix. This
can contribute to crack initiation point. If the filler is brittle fatigue resistance will be
low, whereas if the filler is very ductile the composite will be fatigue
resistant. Adhesion is also an important factor influencing fatigue resistance. If stress
is higher than the particles adhesion a crack will form/propagate. Fiber ends are areas
where cracks initiate most often due to the high stress on fiber ends with lower
adhesion. Talc is a filler that can be used to increase fatigue resistance. [12]

Thermal deformation[edit]
Filler materials have a large influence on thermal deformation in crystalline
polymers. Amorphous polymers are negligibly affected by filler material. Glass fiber
additions are used the most to deflect the most heat. Carbon fibers have been shown to
do better than glass in some base materials. In general fibrous materials are better at
deflecting heat than particle fillers. [12]

Creep[edit]

Creep resistance is heavily impacted by filler materials. The equation below shows the
creep strain of a filled material:[12]

εc(t)/εm(t) = Em/Ec

where:

εc(t) = is strain of filled polymer

εm(t) = is strain of matrix or unfilled polymer
Em = is Young's Modulus of matrix
Ec =is the Young's Modulus of filled polymer

The better the filler bonds with the matrix the better creep resistance will be. Many
interactions will have a positive influence. Glass beads and fibers both have been
shown to improve creep resistance in some materials. Aluminum oxide also has a
positive effect on creep resistance. Water absorption will decrease the creep resistance
of a filled material.[12]

Weldability of plastic fillers[edit]

Additions of filler materials can drastically effect the weldability of the plastic. This
also depends on the type of welding process used. For ultrasonic welding, fillers
like calcium carbonate and kaolin can increase the resin's ability to transmit ultrasonic
waves.[13] For electromagnetic welding and hot plate welding additions
of talc and glass will reduce the weld strength by as much as 32%. [14] The strength of
the plastic after welding would decrease with increasing amount of fillers in the
matrix compared to the bulk material. [15] Use of abrasive fillers can have an effect on
the tool used for welding. Abrasive fillers will degrade the welding tools faster, for
example, the surface of the ultrasonic horn in contact with the plastic. The best way to
test the weldability of a filler material is to compare weld strength to resin strength.
[16]
 This can be hard to do since many filler materials contain different level of
additives that change the mechanical behavior. [16]
Applications of filler in plastic industry[edit]
Filler is a widely used in the production process of plastic products. Filler is used to
change the properties of the original plastic. By using plastic filler, manufacturers can
save production costs as well as raw materials.

Undeniably the importance of filler masterbatch in improving the physical properties

of plastics, especially minimizing cost and production efficiency. With the advantage
of price and stability, plastic filler supports the production of:

 Blow molding
 Blown film & lamination
 Extrusion (pipe, sheet)
 Injection Molding
 Nonwoven fabric
 Raffia
 Thermoforming

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.

rs that improve wear resistance.[12]