Models describing how fillers affect the barrier properties of polymers remain an important research topic to improve applications such as hydrogen storage or food preservation. The Nielsen model, one of the earliest models for such predictions, is still one of the most widely used in the literature. However, it does not provide quantitative information on arrangements of fillers inside a polymer matrix, which is crucial for the definition of suitable filler distributions in barrier materials. Therefore, the channel model was developed in this work, which extends the Nielsen model by determining the relative distances between the fillers in regular filler arrangements in polymer matrices. This allows us to relate the permeation properties of filled polymer membranes to the geometric properties of the filler arrangement in simulations and experimental measurements. Simulations with geometries defined according to the channel model showed good agreement with the predictions of the Nielsen model. This demonstrated that the channel model can be a valuable tool for predicting at least mean geometric distances in studied polymer membranes. The validity range of the channel model was limited to a value range of the filler volume fraction $0.01\le {\varphi }_f\le 0.5$ based on theoretical considerations.

To gain extended knowledge on the flow behavior of polymer melts during filling phase of the injection molding process, an injection mold featuring complex sensor technology was developed. Three triple-combined FOS MTPS408 cavity sensors (FOS Messtechnik GmbH) are aligned along the flow path of a plate-shaped cavity. Each sensor features an infrared detector, a type K thermocouple, and a piezo-electric pressure detector. This configuration enables the local and transient recording of melt temperature, mold temperature and cavity pressure near gate, part center and end of part simultaneously. Averaged melt velocities are determined by evaluating the differing times of the rising edges of the infrared sensors. Local melt velocities and viscosities are calculated at each sensor position by evaluation of the gradients of temperature and pressure. Moreover, the used injection mold is equipped with RHCM technologies to additionally influence the mold surface temperature and hence the filling of the cavity. The specimens are plate-shaped parts having cut-outs and ribs similar to geometries found in numerous industrial applications such as cover panels. The application of this in-mold sensor concept provides novel possibilities for the systematic in-line analysis and evaluation of process-parameters in injection molding. Further studies will be carried out to connect the process-specific properties to the specimen morphology; aiming at controlling morphology by adjusting process parameters.