A proposed model for filler incorporation in polymer fluids in a twin‐screw extruder

Twin‐screw (T/S) extruders are used in the plastics, food, and other industries to perform a variety of critical tasks, or unit operations. Key steps in a modular barrel and screw configuration include solid transport, melting, filler incorporation, filler dispersion and distribution, chemical reactions, degassing, and melt pumping. This paper focuses on the development of a new model to predict the incorporation of particulate fillers into a polymer fluid composite with the production of stable agglomerate aggregates. Since there are little data available in the literature, the model parameters developed are somewhat speculative. However, the predicted trends appear to be consistent with the authors experience with laboratory and industrial compounding processes. The authors recognize that when data becomes available, the model mechanism and parameters will likely need to be updated. Highlights Model of dispersion of filler in co‐rotating twin‐screw extruder. Compressed agglomerate development during polymer–filler composite production. Effect of agglomerate particle–particle cohesive force on size reduction.