Achieving controlled nanoparticle dispersion through melt processing has been challenging as processing-structure rules for polymer nanocomposites are still not well-defined. This work focuses on developing a quantitative understanding of the filler–matrix compatibility and melt mixing parameters on the dispersion of nanoparticles. Filler-matrix compatibility was varied by surface modification of silica nanoparticles. A twin screw extruder was used to prepare the nanocomposites and TEM imaging and image analysis were used to quantitively characterize the microstructure. It was found that matrix–filler compatibility strongly affected the method of agglomerate breakdown and dispersion. Under similar conditions, compatible systems tended to disperse via rupture of agglomerates while incompatible systems were found to disperse via erosion. A map was created to predict the dispersion mechanism as a function of processing conditions and system compatibility and systems from this study and literature were found to be in good agreement with the map.

由于仍未很好地定义聚合物纳米复合材料的加工结构规则，因此通过熔融加工实现受控的纳米颗粒分散一直是一项挑战。这项工作的重点是发展对填料-基体相容性和纳米颗粒分散体上熔融混合参数的定量理解。填料-基质相容性通过二氧化硅纳米颗粒的表面改性而变化。使用双螺杆挤出机制备纳米复合材料，并使用TEM成像和图像分析定量表征微观结构。发现基质与填料的相容性强烈影响团聚体分解和分散的方法。在相似的条件下，相容性体系倾向于通过附聚物破裂而分散，而发现不相容性体系则通过侵蚀而分散。