Fluoropolymer process aids have traditionally been assumed to function most efficiently when present as highly dispersed particles distributed within a polyolefin resin. The current work, however, conclusively demonstrates the superiority of large-particle process aids using in-situ measurements, and demonstrates that fluoropolymer accumulates at the die entrance and flows towards the exit. Practical implications of the findings are discussed, including optimization of fluoroelastomer viscosity and the use of interfacial agents to stabilize the fluoropolymer dispersion.
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