Layered silicate/epoxy nanocomposites: synthesis,characterization and properties

Novel epoxy‐clay nanocomposites have been prepared by epoxy and organoclays. Polyoxypropylene triamine (Jeffamine T‐403), primary polyethertriamine (Jeffamine T‐5000) and three types of polyoxypropylene diamine (Jeffamine D‐230, D‐400, D‐2000) with different molecular weight were used to treat Na‐montmorillonite (MMT) to form organoclays. The preparation involves the ion exchange of Na⁺ in MMT with the organic ammonium group in Jeffamine compounds. X‐ray diffraction (XRD) confirms the intercalation of these organic moieties to form Jeffamine‐MMT intercalates. Jeffamine D‐230 was used as a swelling agent for the organoclay and curing agent. It was established that the d₀₀₁ spacing of MMT in epoxy‐clay nanocomposites depends on the silicate modification. Although XRD data did not show any apparent order of the clay layers in the T5000‐MMT/epoxy nanocomposite, transmission electron microscopy (TEM) revealed the presence of multiplets with an average size of 5 nm and the average spacing between multiplets falls in the range of 100 Å. The multiplets clustered into mineral rich domains with an average size of 140 nm. Scanning electron microscopy (SEM) reveals the absence of mineral aggregate. Nanocomposites exhibit significant increase in thermal stability in comparison to the original epoxy. The effect of the organoclay on the hardness and toughness properties of crosslinked polymer matrix was studied. The hardness of all the resulting materials was enhanced with the inclusion of organoclay. A three‐fold increase in the energy required for breaking the test specimen was found for T5000‐MMT/epoxy containing 7 wt% of organoclay as compared to that of pure epoxy. Copyright © 2004 John Wiley & Sons, Ltd.     

Control of organoclay structure in hydrocarbon polymers

Two different kinds of organoclays were prepared by mixing a pristine montmorillonite and a double‐chain ammonium salt in many different thermoplastic or elastomeric polymers. Independently of the chemical nature of the considered polymers, the obtained organoclays presented a basal spacing of 4 or 6 nm, when the mixing occurred in the absence or in the presence of a small amount of stearic acid (SA), respectively. X‐ray diffraction and Fourier transform infrared measurements support the hypothesis that these two kinds of organoclays correspond to paraffin‐type tilted and perpendicular bi‐layer intercalates, respectively. The co‐intercalation of SA molecules with the double‐chain amphiphile is suggested, to explain the observed expansion of the clay interlayer distance. The obtained results suggest an easy way to control the organoclay structure in polymer composites. Moreover, the authors on the basis of these results propose a criticism to the extensive literature that systematically explains most d basal spacing increase observed for clays in polymer with the penetration of apolar polymer chains in the clay interlayer space. Copyright © 2010 John Wiley & Sons, Ltd.     

Effect of Organoclays on Silicate Layer Structures and Thermal Stabilities of in-situ Polymerized Poly(D-lactide)/Clay Nanocomposites

Six kinds of organoclays were prepared through three kinds of polyols (PTMG, PEA and PCL) to investigate the effects of molecular weight and the chemical structure of organifiers. PTMG based organoclays showed higher ion-exchanged fraction than other organoclays and long chain organifier showed better efficiency in ion-exchanged fraction in the case of PTMG based organifiers. From WAXD and TEM analysis, it was confirmed that PTMG based organoclays formed partially exfoliated or fully exfoliated silicate layer structures. PDLA/clay nanocomposites were prepared by in-situ ring-opening polymerization of D-lactide with PTMG based organoclays as macro-initiators in the presence of equimolar Sn(Oct)₂/PPh₃ complex catalysts. The molecular weight of PDLA/clay nanocomposite decreased as increasing the feeding amount of organoclay because organoclay had hydroxyl terminal groups which can initiate the ring-opening polymerization of D-lactide. From TGA analysis, thermal stabilities of PDLA/clay nanocomposites improved with increasing organoclay content. From WAXD and TEM analysis, organoclay which was prepared by high molecular weight of PTMG based organifier was effective on the exfoliation of silicate layers in the in-situ polymerized PDLA/clay nanocomposite.     

Hydrogen bonding,mechanical properties,and surface morphology of clay/waterborne polyurethane nanocomposites

A novel clay/waterborne polyurethane (WPU) nanocomposite was synthesized from polyurethane and saponite organoclay. The clay was organically modified with various swelling agents, the effect of which has been investigated. Hydrogen bonding between organic and inorganic materials was characterized with Fourier transform infrared (FTIR) spectroscopy. The results implied that hydrogen bonding increased when organoclay was added. Mechanical and wear property studies revealed that introducing clay into waterborne polyurethane will enhance the Young's modulus (from 56 to 126 MPa), the maximum stress (from 3.9 to 7.6 MPa), and the elongation at break (from 27.7 to 58.7%) of the nanocomposite by a factor of two, whereas the wear loss will be only one third of the neat waterborne polyurethane. Atomic force microscopy (AFM) was used to analyze the surface morphology of the nanocomposite. An AFM microphotograph showed that the surface of the clay/waterborne polyurethane nanocomposite was smoother when clay was added in waterborne polyurethane. The average roughness (R_a) decreased from 1.00 to 0.12. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1–12, 2005     

Specific interaction governing the melt intercalation of clay with poly(styrene‐co‐acrylonitrile) copolymers

In the melt intercalation of cation‐exchange clay, mixtures of montmorillonite and poly(styrene‐co‐acrylonitrile) (SAN) with various acrylonitrile contents were studied to examine the effect of specific interaction. When organic molecules with hydroxyl groups were used as intercalants for the clay, the amount of SAN penetrating the gallery of the layered structure of the clay and the corresponding increase in the gallery height occurred at a much higher rate because of the attractive specific interaction between acrylonitrile groups and polar groups on the clay surface. However, there was a limit to the increase in the gallery height, and the tendency for the gallery height to increase with the acrylonitrile group content disappeared when the acrylonitrile content was greater than 30 wt %, implying that excessive attractive interaction on the clay surfaces and polymer molecules glued the two adjacent silicate layers together; consequently, the increase in the gallery height could not be accomplished. © 2001 John Wiley & Sons, Inc. J Polym Sci Part B: Polym Phys 39: 2430–2435, 2001     

Thermal and mechanical properties of syndiotactic polystyrene/organoclay nanocomposites with different microstructures

The fabrication of syndiotactic polystyrene (sPS)/organoclay nanocomposite was conducted via a stepwise mixing process with poly(styrene‐co‐vinyloxazolin) (OPS), that is, melt intercalation of OPS into organoclay followed by blending with sPS. The microstructure of nanocomposite mainly depended on the arrangement type of the organic modifier in clay gallery. When organoclays that have a lateral bilayer arrangement were used, an exfoliated structure was obtained, whereas an intercalated structure was obtained when organoclay with a paraffinic monolayer arrangement were used. The thermal and mechanical properties of sPS nanocomposites were investigated in relation to their microstructures. From the thermograms of nonisothermal crystallization and melting, nanocomposites exhibited an enhanced overall crystallization rate but had less reduced crystallinity than a matrix polymer. Clay layers dispersed in a matrix polymer may serve as a nucleating agent and hinder the crystal growth of polymer chains. As a comparison of the two nanocomposites with different microstructures, because of the high degree of dispersion of its clay layer the exfoliated nanocomposite exhibited a faster crystallization rate and a lower degree of crystallinity than the intercalated one. Nanocomposites exhibited higher mechanical properties, such as strength and stiffness, than the matrix polymer as observed in the dynamic mechanical analysis and tensile tests. Exfoliated nanocomposites showed more enhanced mechanical properties than intercalated ones because of the uniformly dispersed clay layers. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 1685–1693, 2004     

Amine‐cured epoxy/clay nanocomposites. II. The effect of the nanoclay aspect ratio

The thermophysical and mechanical properties of a nanocomposite material composed of amine‐cured diglycidyl ether of bisphenol A (DGEBA) reinforced with organomontmorillonite clay are reported. The storage modulus at 100 °C, which was above the glass‐transition temperature (T_g), increased approximately 350% with the addition of 10 wt % (6.0 vol %) of clay. Below the T_g, the storage modulus at 30 °C increased 50% relative to the value of unfilled epoxy. It was determined that the T_g linearly increased as a function of clay volume percent. The tensile modulus of epoxy at room temperature increased approximately 50% with the addition of 10 wt % of clay. The reinforcing effect of the organoclay nanoplatelets is discussed with respect to the Tandon–Weng and Halpin–Tsai models. A pseudoinclusion model is proposed to describe the behavior of randomly oriented, uniformly dispersed platelets in nanocomposite materials. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 4391–4400, 2004     

Nanocomposites of poly(ethylene terephthalate‐co‐ethylene naphthalate) with organoclay

Poly(ethylene terephthalate‐co‐ethylene naphthalate) (PETN)/organoclay was synthesized with the solution intercalation method. Hexadecylamine was used as an organophilic alkylamine in organoclay. Our aim was to clarify the intercalation of PETN chains to hexadecylamine–montmorillonite (C₁₆–MMT) and to improve both the thermal stability and tensile property. We found that the addition of only a small amount of organoclay was enough to improve the thermal stabilities and mechanical properties of PETN/C₁₆–MMT hybrid films. Maximum enhancement in both the ultimate tensile strength and initial modulus for the hybrids was observed in blends containing 4 wt % C₁₆–MMT. Below a 4 wt % clay loading, the clay particles could be highly dispersed in the polymer matrix without a large agglomeration of particles. However, an agglomerated structure did form in the polymer matrix at a 6 wt % clay content. © 2001 John Wiley & Sons, Inc. J Polym Sci Part B: Polym Phys 39: 2581–2588, 2001     

Effects of organoclays on the thermal processing of pe/clay nanocomposites

Nanocomposites containing both polyethylene and montmorillonite clay organically modified with four different types of quaternary ammonium salts were obtained via direct melt intercalation. Thus, the main purpose of this work was to evaluate the effect of the organoclay on the thermal stability of polyethylene. The organoclays were characterized by XRD, FTIR, DSC and TG. The polyethylene/organoclay nanocomposites were studied by XRD, TEM, TG, besides an evaluation of their mechanical properties. The results showed that the salts were incorporated by intercalation between the layers of the organoclay and, apparently that the nanocomposites were more thermally stable than pure polyethylene.     

Studies on structure property relationship in a polymer–clay nanocomposite film based on (PAN)8LiClO4

A new combination of ionically conducting polymer–clay nanocomposites based on (PAN)₈LiClO₄ + x wt % montmorillonite (unmodified) clay has been prepared using the standard solution cast process. X-Ray diffraction (XRD) analysis reveals strong interaction of polymer salt complex (PS) with the montmorillonite matrix evidenced by changes in d₀₀₁ spacing of the clay and enhancement in the clay gallery width on composite formation possibly due to intercalation of polymer–salt complex into nanometric clay galleries. Evidences of such an interaction among polymer–ion–clay components of the composite matrix has also been observed in the Fourier transform infrared (FTIR) spectrum results. FTIR results clearly indicated cation (Li⁺) coordination at nitrile (CN) site of the polymer backbone along with appearance of a shoulder suggesting strong evidence of polymer–ion interaction. Addition of clay into the PS matrix has been observed to affect ion–ion interaction resulting from ion dissociation effect at low clay loading in the PNC films. Complex impedance spectroscopy (CIS) analysis has provided a response comprising of a semicircular arc followed by a spike attributed respectively, to the bulk conduction and electrode polarization at the interfaces. Electrical transport appears to be predominantly ionic (t_ion = 0.99) with significant improvement in the electrical conductivity and thermal stability properties. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 2577–2592, 2008     

Polyolefin-based nanocomposite: The effect of organoclay modifier

Polypropylene (PP) nanocomposites were prepared using montmorillonite with different organic modifiers, and the effect of processing aid (EMCA and PPG) on the dispersion of the nanofillers in the PP matrix was evaluated by WAXD, TEM, DSC, TGA, DMA, and mechanical tests. The present study helps to clarify the effects of the organic modifiers of clays on the intercalation and exfoliation processes. Nanocomposites of intercalated and partially exfoliated morphology were obtained, mainly when a low amount (1:1) of PP-g-MA/MMT was used. The results of the tests on mechanical properties showed that the clays with larger d₀₀₁ (C-15A and Nanofil 5) using PPG presented a more considerable gain in impact strength. The nanocomposites using clays with smaller d₀₀₁(C-20A) presented larger modulus when compared with those of pristine PP. The heat deflection temperature, crystallization temperature, and thermal stability of the nanocomposites were improved compared to neat PP. The DMA results showed that the organoclay improved the modulus of PP, but decreased the T_g. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 2519–2531, 2008     

Influence concentration of modifying agent on properties of natural rubber/organoclay nanocomposites

Sodium-montmorillonite (Na-MMT) nanoclay was modified with different concentrations of octadecylamine organic modifying agent at 0.5, 1.0 and 1.5 times the CEC of Na-MMT. Influence of concentration of modifying agent on properties of the organoclays and natural rubber/organoclay nanocomposites was investigated. It was found that the optimum concentration of modifying agent was 1.5 times the CEC of Na-MMT. That is, at this concentration, larger d-spacing of organoclay particles and higher degree of clay dispersion in natural rubber matrix were observed. Larger interlayer d-spacing also caused enhancement of the mechanical properties of the NR/organoclay nanocomposites. Additionally, the NR/organoclay nanocomposites with higher concentration of modifying agent exhibited faster curing reaction with higher crosslink density. Furthermore, the organoclays with larger d-spacing and higher degree of dispersion in the natural rubber matrix exhibited enhancement of the mechanical and dynamic properties and thermal stability of natural rubber/organoclay nanocomposites.     

Nanocomposites of polyurethane with various organoclays: Thermomechanical properties,morphology, and gas permeability*

The properties of polyurethane (PU) nanocomposites with three different organoclays were compared in terms of their thermal stabilities, mechanical properties, morphologies, and gas permeabilities. Hexadecylamine–montmorillonite, dodecyltrimethyl ammonium–montmorillonite, and Cloisite 25A were used as organoclays for making PU hybrid films. The properties were examined as a function of the organoclay content in a matrix polymer. Transmission electron microscopy photographs showed that most clay layers were dispersed homogeneously into the matrix polymer on the nanoscale, although some particles of clay were agglomerated. Moreover, the addition of only a small amount of organoclay was enough to improve the thermal stabilities and mechanical properties of PU hybrid films, whereas gas permeability was reduced. Even polymers with low organoclay contents (3–4 wt %) showed much higher strength and modulus values than pure PU. Gas permeability was reduced linearly with an increasing amount of organoclay in the PU matrix. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 670–677, 2002; DOI 10.1002/polb.10124     

Crystallization behavior and thermal stability of poly(trimethylene terephthalate)/clay nanocomposites

Poly(trimethylene terephthalate) (PTT)/montmorillonite (MMT) nanocomposites were prepared by the solution intercalation method. Two different kinds of clay were organomodified with an intercalation agent of cetyltrimetylammonium chloride (CMC). X‐ray diffraction (XRD) indicated that the layers of MMT were intercalated by CMC, and interlayer spacing was a function of the cationic exchange capacity of clay. The XRD studies demonstrated that the interlayer spacing of organoclay in the nanocomposites depends on the amount of organoclay. From the results of differential scanning calorimetric analysis, it was found that clay behaves as a nucleating agent and enhances the crystallization rate of PTT. The maximum enhancement of the crystallization rate for the nanocomposites was observed in nanocomposites containing about 1 wt % organoclay with a range of 1–15 wt %. From thermogravimetric analysis, we found that the thermal stability of the nanocomposites was enhanced by the addition of 1–10 wt % organoclay. According to transmission electron microscopy, the organoclay particle was highly dispersed in the PTT matrix without a large agglomeration of particles for a low organoclay content (5 wt %). However, an agglomerated structure did form in the PTT matrix at a 15 wt % organoclay content. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 2902–2910, 2003     

Synthesis and electrorheological characterization of emulsion polymerized SAN‐clay nanocomposite suspensions

Styrene‐acrylonitrile (SAN) copolymer‐clay nanocomposite was synthesized by emulsion polymerization, which is the easiest method of intercalation (e.g., melt or solution intercalation). Existence of the intercalated polymer was verified by Fourier transform‐infrared spectroscopy and X‐ray diffraction (XRD) analysis. From XRD, we confirmed the insertion of styrene‐acrylonitrile copolymer between the interlayers of clay, whose separation consequently becomes larger than that of the polymer‐free clay. Thermogravimetric analysis showed that the thermal stability of the organic polymers was sustained. Using electrorheological (ER) fluids composed of intercalated particles and silicone oil, we observed typical ER behavior, such as higher shear stress in the presence of an electric field and increasing yield stress with particle concentration. We further observed the critical shear rate at which the ER fluids exhibit pseudo‐Newtonian behavior.     

Designed organo‐layered silicates as nanoreactors for 1,3‐butadiene stereospecific polymerization toward rubber nanocomposites synthesis

Organo‐modified layered silicates were synthesized and used as inorganic carriers for CoCl₂(P^tBu₂Me)₂‐MAO catalyst in the polymerization of 1,3‐butadiene, yielding cis‐1,4‐enriched polybutadiene. The organoclays were prepared by: (i) intercalation of (ar‐vinyl‐benzyl)trimethyl ammonium chloride salt through an ion exchange reaction, and (ii) the edge‐surface grafting by trimethylchlorosilane. The ammonium modifier acts as “spacer” increasing the layer d‐spacing and as “filler” favoring the silylation of the edge‐surface clay hydroxyls. The grafted silane prevents the MAO cocatalyst from reacting with the edge‐OHs, by forcing it to react within the interlayer clay region. MAO lead to methylation of the cobalt complex and carbanion abstraction to give a cobalt‐methyl cation that is stabilized by the MAO anion. The nanoconfined cationic alkylated species insert the butadiene on the Co‐Me bond affording the growth of the polymer chains within the clay layers. The growing of the macromolecular chains fills the interlayer silicate region giving an intercalated polybutadiene rubber nanocomposite. The role of the silicate organo modification on the heterogeneous catalyst structural features, the polymerization behavior and the nanocomposite structures are discussed. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2010     

Polypropylene/organoclay nanocomposites compatibilized with hydroxyl‐functional polypropylenes

The properties of polypropylene composites can be tailored through the use of nanoclay fillers. The effectiveness of a metallocene‐catalyzed hydroxyl‐functional polypropylene in the compatibilization of polypropylene layered nanosilicate composites was studied, and the results were compared with those for a commercial maleic anhydride functionalized polypropylene. Polypropylene/organoclay nanocomposites were prepared by melt blending, and two polypropylene/compatibilizer/organoclay ratios, 90/5/5 and 70/20/10, were characterized. The organomodification of the clay was carried out with octadecylamine and N‐methylundecenylamine. The structure of the layered silicate was studied by transmission electron microscopy, wide‐angle X‐ray scattering, and small‐angle X‐ray scattering. The fracture surfaces of the composites and thus the efficiency of the compatibilizers to penetrate the galleries of the organoclays were characterized by scanning electron microscopy, and the melt viscosity was studied by stress‐controlled rotational rheometry. The nanostructure was observed with both alkyl amines used for intercalation. The fillers facilitated the processability of all the composites, consisting of equal amounts of compatibilizer and organoclay filler and, in some of the composites, containing twice as much compatibilizer as organoclay filler. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1892–1903, 2005     

Poly(lactic acid) nanocomposites with various organoclays. I. Thermomechanical properties,morphology, and gas permeability

The thermomechanical properties, morphology, and gas permeability of hybrids prepared with three types of organoclays were compared in detail. Hexadecylamine–montmorillonite (C₁₆–MMT), dodecyltrimethyl ammonium bromide–montmorillonite (DTA‐MMT), and Cloisite 25A were used as organoclays in the preparation of nanocomposites. From morphological studies using transmission electron microscopy, most clay layers were found to be dispersed homogeneously in the matrix polymer, although some clusters or agglomerated particles were also detected. The initial degradation temperature (at a 2% weight loss) of the poly(lactic acid) (PLA) hybrid films with C₁₆–MMT and Cloisite 25A decreased linearly with an increasing amount of organoclay. For hybrid films, the tensile properties initially increased but then decreased with the introduction of more of the inorganic phase. The O₂ permeability values for all the hybrids for clay loadings up to 10 wt % were less than half the corresponding values for pure PLA, regardless of the organoclay. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 94–103, 2003     

A new hybrid nanocomposite prepared by emulsion copolymerization of ABS in the presence of clay

The preparation and characterizations of new hybrid organic–inorganic nanocomposites consisting of acrylonitrile–butadiene–styrene terpolymer and a Na⁺‐exchanged montmorillonite (MMT) are described by direct intercalation through one‐step emulsion polymerization. Those products were purified by successive hot acetone and toluene extraction, respectively, for more than 2 days. The IR spectra for the purified samples revealed the characteristic absorbances as a result of those of styrene, butadiene, acrylonitrile, and MMT. X‐ray diffraction spectra of the composites showed the enlarged 001 d‐spacing as much as 1.75 nm, but no signals were found for the partial insertion of copolymer chains. Moreover, it was evident that this direct intercalation was not accompanied by delamination of the clay interlayer. The thermogravimetric analytic measurement for the purified product confirmed that the onset temperature of decomposition was transferred to the higher temperature region as much as 40–50 °C. Morphological observations by transmission electron microscopy, scanning electron microscopy, and optical micrography demonstrated homogeneous dispersion of MMT particles in the copolymer matrix. The possible physical picture of this direct intercalation was discussed in terms of swelling characteristics of compacted bentonite and the monomer containing micelle sizes. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 719–727, 2001     

Review of melt‐processed nanocomposites based on EVOH/organoclay

EVOH nanocomposites containing organically treated clays are unique systems in which the clay is strongly attracted to EVOH, thus affecting the morphology and the resultant thermal and mechanical properties. A strong effect of the processing conditions on morphology, thermal, and mechanical properties was observed. In highly interacting systems, under dynamic mixing conditions, in addition to a fracturing process of the clay particles, an onion‐like delamination process is suggested. EVA‐g‐MA and LLDPE‐g‐MA, having polar groups, were studied as compatibilizers to further induce clay intercalation and exfoliation. The compatibilizers affected both the thermal and mechanical properties of the composites at different levels. Thermal analysis showed that with increasing compatibilizer content lower crystallinity levels result, until at a certain content no crystallization has taken place. A Ny‐6 (nylon‐6)/EVOH blend is an interesting host matrix for incorporation of low organoclay contents. The Ny‐6/EVOH blend is a unique system that tends to hydrogen bond and also to in situ chemically react during melt mixing. The addition of clay seems to interrupt the chemical reaction between the two host polymers at certain compositions, leading to lower melt blending torque levels when clay is present. A competition between Ny‐6 and EVOH regarding the intercalation process takes place. However, Ny‐6 seems to lead to exfoliated structures, whereas EVOH forms intercalated structures, as revealed from combined XRD and TEM experiments, owing to thermodynamic considerations and preferential localization of the clay in Ny‐6. Of special interest is the increased storage modulus seen by the presence of only 1 wt % clay, which was achieved by extrusion under high shear forces, leading to a completely exfoliated structure. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1931–1943, 2005