Processing and characterization of epoxy/clay nanocomposites

Nanocomposite materials consisting of an epoxy matrix and silicate clay particles have been processed and characterized mechanically. The clay material used was a modified natural montmorillonite. The clay particles consisted of 1 nm thick layers with aspect ratios in the range of 100–1000. The clay particles were mixed with acetone and sonicated, then mixed with the polymer, deaerated and cured. The ultimate objective of processing was to produce a polymer/clay nanocomposite with separated (exfoliated) platelets, dispersed as uniformly as possible. Samples were prepared with clay concentrations of up to 10 wt%. The process used resulted in limited exfoliation but mostly intercalation, i.e., infusion of polymer between the silicate layers and increase of interlayer spacing. The characteristics of the nanocomposite were assessed by transmission electron microscopy and x-ray diffraction. Results from these observations show that the basal spacing of clay platelets increased from an initial pre-processing value of 1.85 nm to 4.5 nm. Enhancement of mechanical properties was measured by tensile testing of coupons. Stiffness increases of up to 50% over that of the unfilled epoxy were measured for clay concentrations of 5 wt%. Strength increases were also measured for low clay concentrations and low strain rate loading. Micromechanics modeling of mechanical behavior is discussed as a function of clay platelet dispersion.