Inorganic vs Organic fillers: What are the differences? - EuroPlas

Inorganic vs Organic fillers: What are the differences?

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Fillers, also known as extenders, are materials added to a matrix to improve its properties or reduce its cost. They are widely used in various industries, including plastics, paints, coatings, adhesives, and composites. Fillers can be classified into two main categories: inorganic and organic. Understanding the key differences between inorganic vs organic fillers is essential for selecting materials that meet your specific needs.

1. Exploring Inorganic Fillers

1.1. What are Inorganic Fillers?

Inorganic fillers are solid substances that do not contain carbon and are added to various materials such as plastics, rubber, glass, metals, etc., to enhance certain properties of those materials. Inorganic fillers can be divided into two main types:

• Mechanical Fillers: These fillers are added to improve the mechanical properties of the material, such as tensile strength, elasticity, impact resistance, etc.
• Surface-Active Fillers: These fillers are added to enhance the surface properties of the material, such as gloss, slipperiness, water resistance, etc.

What are Inorganic Fillers?

1.2. Common Inorganic Fillers

There are various types of inorganic fillers, but some of the most common ones include:

• Calcium Carbonate (CaCO3): Calcium carbonate is a naturally occurring limestone with a white or gray color. It is widely used as a filler in plastics, rubber, paint, and paper. Calcium carbonate can help reduce costs while increasing the hardness, durability, and heat resistance of the material.
• Talc (Mg3Si4O10(OH)2): Talc is a silicate mineral with a white or gray color. It is often used as a filler in plastics, rubber, and paint. Talc can contribute to cost reduction while enhancing the hardness, durability, and smoothness of the material.
• Gypsum (CaSO4·2H2O): Gypsum is a sulfate mineral with a white or gray color. It is commonly used as a filler in plastics, rubber, and paint. Gypsum can help reduce costs while increasing hardness, durability, and sound absorption properties of the material.
• Mica (KAl2(AlSi3O10)(OH)2): Mica is a silicate mineral with a white or gray color. It is frequently used as a filler in plastics, rubber, and paint. Mica can contribute to increased hardness, durability, and fire resistance of the material.
• Calcium Silicate (CaSiO3): Calcium silicate is a silicate mineral with a white or gray color. It is commonly used as a filler in plastics, rubber, and paint. Calcium silicate can help enhance hardness, durability, and heat resistance of the material.

1.3. Applications of Inorganic Fillers

Specific applications of inorganic fillers in the plastics industry include their use to reduce costs, enhance rigidity, durability, and heat resistance of plastics. Inorganic fillers are commonly employed in the production of plastic products such as household items, packaging, and electronic components.

• Cost reduction: Inorganic fillers can significantly reduce the cost of plastics by up to 50%. This makes plastic more affordable and suitable for a broader range of applications.
• Increased rigidity and durability: Inorganic fillers contribute to increased rigidity and durability of plastics, making them more sturdy and less prone to deformation.
• Enhanced heat resistance: Inorganic fillers improve the heat resistance of plastics, making them more suitable for applications that involve high temperatures.

Inorganic fillers find wide-ranging applications in various industries, including rubber, paint, paper, ceramics, and plastics.

Exploring Inorganic Fillers

2. Exploring Organic Fillers

2.1. What are Organic Fillers?

Organic fillers are materials of natural origin added to other materials, such as polymers and plastics, to alter their properties. In contrast to inorganic fillers, which are materials devoid of carbon, organic fillers are added to plastics to improve their mechanical, electrical, thermal, optical, chemical, or processing characteristics. Organic fillers often have a lower cost compared to virgin plastics, thus contributing to reducing plastic manufacturing expenses.

2.2. Common types of Organic Fillers

There are numerous types of organic fillers used in the plastics industry. Some common types of organic fillers include:

• Wood powder: Wood powder is one of the most common organic fillers, made by grinding wood into fine particles. It can enhance various properties of plastics, such as strength, hardness, electrical conductivity, thermal conductivity, corrosion resistance, etc.
• Chicken feather: Chicken feathers are a low-cost organic filler that can improve properties such as strength, hardness, electrical conductivity, thermal conductivity, corrosion resistance, etc.
• Rice husk: Rice husk is an organic filler derived from rice plants. It can enhance properties like strength, hardness, electrical conductivity, thermal conductivity, corrosion resistance, etc.
• Cellulose: A versatile filler derived from wood pulp, used to improve strength, hardness, and water absorption properties.
• Starch: A bio-based filler used to enhance flexibility, adhesion, and film-forming properties.
• Natural fibers: Fibers from plants such as flax, jute, and hemp are used to improve strength, hardness, and biodegradability.
• Synthetic polymers: Polymers like polyvinyl alcohol (PVA) and polyethylene glycol (PEG) are used to enhance flexibility, adhesion, and film-forming properties.

Additionally, there are other organic fillers used in the plastics industry, such as:

• Recycled rubber powder: Made from discarded rubber.
• Factice: A synthetic rubber made from wood and fatty oils.
• Silica: A mineral filler that can be used to enhance mechanical strength and fire resistance of plastics.

Exploring Organic Fillers

2.3. Applications of Organic Fillers in composite materials

Organic fillers are increasingly finding applications in various industries due to their sustainability and performance benefits. Here are some examples:

• Automotive: Organic fillers are utilized in automotive components such as dashboards, door panels, and interior decorative parts.
• Construction: Organic fillers are employed in construction materials, including flooring, insulation materials, and panels.
• Packaging: Organic fillers are used in packaging materials to reduce environmental impact and enhance their biodegradability.
• Consumer goods: Organic fillers are incorporated into various consumer goods, including electronic devices, sporting goods, and toys.
• Medical applications: Organic fillers are being explored for use in medical applications such as tissue engineering and wound healing techniques.

3. Inorganic vs Organic fillers: What are the differences?

Fillers play a crucial role in modifying material properties, enhancing their performance, and providing cost-effective solutions. Understanding the key differences between inorganic and organic fillers is essential for selecting materials that meet your specific needs.

Feature

Inorganic Fillers

Organic Fillers

Origin

Non-living sources, derived from non-living sources like minerals, rocks, and metals. Examples include silica, calcium carbonate, and aluminum oxide.

Living organisms or their byproducts

Chemical composition

Composed of elements like silicon, calcium, aluminum, and magnesium. They are typically inorganic salts, oxides, or silicates.

Primarily composed of carbon, hydrogen, and oxygen. They may also contain other elements like nitrogen and sulfur. They often consist of complex organic molecules like cellulose, lignin, and chitin.

Density

Generally denser than organic fillers. For example, calcium carbonate has a density of 2.71 g/cm³, while wood flour has a density of 0.4 g/cm³.

Often less dense than inorganic fillers, making them attractive for weight-sensitive applications.

Cost

Generally more affordable than organic fillers due to their abundant availability and simpler processing.

Can be more expensive due to limited sources and potentially complex processing methods.

Properties

Improve stiffness, strength, hardness, and thermal stability. However, they can reduce flexibility and impact resistance.

Can improve strength, stiffness, and dimensional stability while reducing weight and improving biodegradability. However, they may be susceptible to moisture and degradation.

Biodegradability

Generally non-biodegradable, meaning they will not decompose naturally.

Often biodegradable, meaning they can be broken down by microorganisms over time. This offers environmental benefits and reduces landfill waste.

Environmental impact

Mining and processing inorganic fillers can have negative environmental impacts, including air and water pollution.

Can offer a more sustainable option due to their renewable nature and biodegradability. However, some organic fillers require significant processing, which may have environmental impacts.

 

The optimal choice between inorganic and organic fillers depends on your specific needs and priorities. Consider factors such as the required properties, cost, environmental impact, and desired functionality.

In applications demanding high strength and rigidity, inorganic fillers may be preferred. For weight-sensitive applications with environmental concerns, organic fillers could be a better choice.

Are you interested in learning more about Inorganic friction powder for automotive? Contact us today to secure an expert consultation!

4. Frequently asked questions

Can inorganic and organic fillers be used together?

Yes, inorganic and organic fillers can be combined to yield the best benefits for polymer materials. For example, inorganic fillers can be used to enhance the stiffness and durability of the material, while organic fillers can be used to improve elasticity and water resistance.

What are the benefits of inorganic fillers?

Inorganic fillers can provide the following benefits to polymer materials:

• Enhance stiffness, durability, and heat resistance.
• Reduce the weight of the material.
• Improve fire resistance.
• Increase electrical or thermal conductivity.

What are the benefits of organic fillers?

Organic fillers can offer the following benefits to polymer materials:

• Enhance material elasticity.
• Improve water resistance.
• Increase UV resistance.
• Reduce material costs.

Which type of filler is better?

The choice between inorganic and organic fillers depends on the specific application of the polymer material. For applications requiring high stiffness, durability, and heat resistance, inorganic fillers are often a better choice. For applications demanding elasticity, water resistance, or lower cost, organic fillers are generally a preferable option.

Can inorganic and organic fillers replace each other?

In some cases, inorganic and organic fillers can replace each other, but not in all cases. For instance, inorganic fillers can replace organic fillers in applications that demand high stiffness, durability, and heat resistance. However, organic fillers cannot replace inorganic fillers in applications requiring elasticity, water resistance, or lower cost.

5. Conclusion

Inorganic and organic fillers are two common types of fillers used in various industries. The main difference between these two types of fillers lies in their physical properties and chemical composition. Both inorganic and organic fillers have their own advantages and disadvantages. The selection of a suitable filler depends on the specific requirements of the application and the industry of production.

 

Solid lubricants can be utilized as free-flowing powders, as additives in some oils and greases, and as key ingredients in high-performance anti-friction coatings and anti-seize pastes. These special lubricant additives and powders fill in and level surface asperity valleys and peaks thanks to their adherence to the substrate and coherence between them.

The solids deliver efficient boundary lubrication, improving friction and minimizing wear under extreme operating environments. Contrary to grease or oil fluid films for hydrodynamic lubrication, boundary films created by solid lubricants are capable of maintaining a uniform thickness irrespective of speed, temperature and load.

Types and Characteristics of Solid Lubricants

Solid lubricants are available in various compositions with different properties. This application note describes the common types of solid lubricants utilized in Molykote brand anti-friction coatings and anti-seize pastes.

Copper is a soft metal with high plasticity and low shear strength, providing it good lubricating capabilities.

Benefits of soft-metal solid lubricants include:

• High-temperature stability
• High load-carrying capacity

However, they cannot be utilized with stainless steel at temperatures more than 1,000 °C due to the chance for galvanic corrosion.

Graphite with a layered lattice structure and weak bonding between layers delivers superior lubricity as long as the presence of moisture.

Benefits of graphite solids include:

• Good lubrication in high humidity
• Protection against fretting corrosion
• High-temperature stability
• Low coefficient of friction under high loads

Polytetrafluoroethylene (PTFE) comprises carbon and fluorine atoms and is recognized as one of the most slippery manmade materials due to its low surface tension.

Advantages of PTFE solids include:

• Good sliding-friction reduction
• Good chemical resistance
• Low load-carrying capacity
• Low coefficient of friction at low loads
• Colorless film lubricity

Molybdenum disulfide with a lamellar structure can be sheared easily in the motion direction. It is possible to match particle size and film thickness to match surface roughness.

Benefits of molybdenum disulfide solid lubricants include

• Excellent adhesion
• Wide service-temperature range
• Protection against fretting corrosion
• Decreased friction with increasing loads
• Stick-slip prevention
• High load-carrying capacity

Molybdenum disulfide solid lubricants cannot be utilized in wet conditions as moisture increases friction.

White solids are different types of inorganic compounds and capable of forming a reactive lubricating layer for better wear protection.

Other advantages of white solids include

• Resistance to high temperatures
• Good protection against fretting corrosion

Product Selection by Ingredients

Normally, anti-friction coatings will comprise around 30% solids blended with a resin binder and solvent carrier, while anti-seize pastes will consist of 40% to 60% solids in a base-oil carrier. Oils and greases may contain up to 10% of solids for lubrication during shock-load, start-up and shutdown conditions.

Solid lubricants such as graphite and molybdenum disulfide normally demonstrate higher load-carrying capacity of up to 1,000 N/mm2. They can play a role in preventing cold-welding and galling and are capable of providing lifetime lubrication under dirty and dusty conditions.

Although the load-carrying capacity of PTFE is on the lower side (up to250 N/mm2), it facilitates achieving a low coefficient of friction in sliding-load conditions. Metal pastes can be utilized as anti-seize compounds on threaded connections. Metal-free white pastes are ideal option for extreme heat applications and for preventing stress-corrosion cracking and solder embrittlement.

Performance Improvement with Different Combinations

It is possible to combine different types of solid lubricants in a coating or paste formulation to deliver certain synergistic results such as improved fretting-corrosion protection, optimal friction control and wear prevention, and increased load-carrying capacity. The advantages of using different combinations of solid lubricants are better than that of individual solid lubricants.

This information has been sourced, reviewed and adapted from materials provided by Dow Corning.

For more information on this source, please visit Dow Corning.

Contact us to discuss your requirements of Industrial friction powders. Our experienced sales team can help you identify the options that best suit your needs.