Continuous film casting of polycarbonate/single‐walled carbon nanotubes composites with ultrasound‐assisted twin‐screw extruder: Effect of screw configuration

Abstract Polymer films are widely used in various industries, and incorporation of nanofillers into polymer films can give much more versatility in their applications. Polymer/carbon nanotubes (CNTs) composite films with good electrical conductivity can easily find applications in anti‐static or electrostatic discharge (ESD) protection. In the present study, efforts were devoted to investigate novel ultrasound‐assisted twin‐screw extrusion technology on improving the dispersion and distribution of single‐walled carbon nanotubes (SWNTs) in polycarbonate (PC) composites films via extrusion process. As a key processing parameter, effect of screw configuration on the performance of the composite films were systematically studied. Electrical, rheological, morphological and mechanical properties were characterized to illustrate the processing‐structure–property relationship during continuous film casting of PC/SWNTs composites with ultrasound‐assisted twin‐screw extruder. Results indicated that the screw configuration containing more kneading blocks led to better SWNTs dispersion and distribution, while the effect of ultrasound was more prominent in screw design with less kneading blocks.