Abstract
We developed a simple analytical model to describe the instantaneous location and angle of rod-like conductive fillers as a function of cell growth during the foaming of conductive polymer composites (CPCs). First, we modelled the motion of the fillers that resulted from the growth of one cell. Then, by taking into account the fillers located at the line that connected the centres of the two growing cells, we found the final filler's angle and location. We identified this as a function of the corresponding cell size, filler size, and the filler's initial angle and location. We based the model's development on the assumption that a polymer melt is incompressible during cell growth. The two-cell growth model is better than the one-cell growth model because it describes the filler's movement in the cell wall between the two growing cells. The results revealed that the fillers near the cell were the ones most affected by the cell growth, while those at the midpoint between the two cells were the least affected. As a cell grows, its affected polymer area also increases. A dimensionless factor η was introduced to demonstrate the effects of the cell size and the filler length on the filler's interconnectivity in the CPC foams. It is vital to keep the filler length comparable to the cell size when preparing CPC foams with the desired electrical conductivity. Our research provides a deeper understanding of the mechanism through which foaming influences the filler connections in CPC foams.