Novel synthesis of nano‐calcium carbonate (CaCO3)/polystyrene (PS) core–shell nanoparticles by atomized microemulsion technique and its effect on properties of polypropylene (PP) composites

Calcium carbonate (CaCO₃)/polystyrene (PS) nanoparticles (<100 nm) with core–shell structure were synthesized by atomized microemulsion technique. The polymer chains were anchored onto the surface of nano‐CaCO₃ through triethoxyvinyl silane (TEVS) as a coupling agent. Ammonium persulfate (APS), sodium dodecyl sulfate (SDS) and n‐pentanol were used as initiator, surfactant, and cosurfactant, respectively. Polymerization mechanism of core–shell latex particles was discussed. Encapsulation of nano‐CaCO₃ by PS was confirmed by using transmission electron microscope (TEM). Grafting percentage of core–shell particles was investigated by Thermogravimetric Analyzer (TGA). Nano‐CaCO₃/PS core–shell particles were characterized by Fourier transform infrared (FTIR) spectrophotometer and differential scanning calorimeter (DSC). The results of FTIR revealed existence of a strong interaction at the interface of nano‐CaCO₃ particle and PS, which implies that the polymer chains were successfully grafted onto the surface of nano‐CaCO₃ particle through the link of the coupling agent. In addition, TGA and DSC results indicated an enhancement of thermal stability of core–shell materials compared with the pure nano‐PS. Nano‐CaCO₃/PS particles were blended with polypropylene (PP) matrix on Brabender Plastograph by melt process with different wt% of loading (i.e. 0.1–1 wt%). The interfacial adhesion between nano‐CaCO₃ particles and PP matrix was significantly improved when the nano‐CaCO3 particles were grafted with PS, which led to increased thermal, rheological, and mechanical properties of (nano‐CaCO₃/PS)/PP composites. Scanning electron microscope (SEM) and atomic force microscope (AFM) images showed a perfect dispersion of the nano‐CaCO₃ particles in PP matrix. Copyright © 2011 John Wiley & Sons, Ltd.