As for nanofillers in general, the properties of carbon nanotube (CNT) -polymer composites depend strongly on the filler arrangement and the structure of the filler network. This article reviews our actual understanding of the relation between processing conditions, state of CNT dispersion and structure of the filler network on the one hand, and the resulting electrical, melt rheological and mechanical properties, on the other hand. The as-produced rather compact agglomerates of CNTs (initial agglomerates, >1 µm), whose structure can vary for different tube manufacturers, synthesis and/or purification conditions, have first to be well dispersed in the polymer matrix during the mixing step, before they can be arranged to a filler network with defined physical properties by forming secondary agglomerates. Influencing factors on the melt dispersion of initial agglomerates of multi-walled CNTs into individualized tubes are discussed in context of dispersion mechanisms, namely the melt infiltration into initial agglomerates, agglomerate rupture and nanotube erosion from agglomerate surfaces. The hierarchical morphology of filler arrangement resulting from secondary agglomeration processes has been found to be due to a competition of build-up and destruction for the actual melt temperature and the given external flow field forces. Related experimental results from in-line and laboratory experiments and a model approach for description of shear-induced properties are presented

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. Influence of screw configuration, residence time, and specific mechanical energy in twin-screw extrusion of polycaprolactone/multi-walled carbon nanotube composites.

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This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. AbstractBall milling of carbon nanotubes (CNTs) in the dry state is a common way to produce tailored CNT materials for composite applications, especially to adjust nanotube lengths. For Nanocyl TM NC7000 nanotube material before and after milling for 5 and 10 hours the length distributions were quantified using TEM analysis, showing decreases of the mean length to 54 and 35%, respectively. With increasing ball milling time in addition a decrease of agglomerate size and an increase of packing density took place resulting in a worse dispersability in aqueous surfactant solutions. In melt mixed CNT polycarbonate composites produced using masterbatch dilution step the electrical properties, the nanotube length distribution after processing, and the nano-and macrodispersion of the nanotubes were studied. The slight increase in the electrical percolation threshold in the melt mixed composites with ball milling time of CNTs can be assigned to lower nanotubes lengths as well as the worse dispersability of the ball milled nanotubes. After melt compounding, the mean CNT lengths were shortened to 31%, 50%, and 66% of the initial lengths of NC7000, NC7000-5h, and NC7000-10h, respectively.