A critical appraisal of polymer-clay nanocomposites

The surge of interest in and scientific publications on the structure and properties of nanocomposites has made it rather difficult for the novice to comprehend the physical structure of these new materials and the relationship between their properties and those of the conventional range of composite materials. Some of the questions that arise are: How should the reinforcement volume fraction be calculated? How can the clay gallery contents be assessed? How can the ratio of intercalate to exfoliate be found? Does polymerization occur in the clay galleries? How is the crystallinity of semi-crystalline polymers affected by intercalation? What role do the mobilities of adsorbed molecules and clay platelets have? How much information can conventional X-ray diffraction offer? What is the thermodynamic driving force for intercalation and exfoliation? What is the elastic modulus of clay platelets? The growth of computer simulation techniques applied to clay materials has been rapid, with insight gained into the structure, dynamics and reactivity of polymer-clay systems. However these techniques operate on the basis of approximations, which may not be clear to the non-specialist. This critical review attempts to assess these issues from the viewpoint of traditional composites thereby embedding these new materials in a wider context to which conventional composite theory can be applied. (210 references).     

Shear-induced structure in polymer-clay nanocomposite solutions

The equilibrium structure and shear response of model polymer-clay nanocomposite gels are measured using X-ray scattering, light scattering, optical microscopy, and rheometry. The suspensions form physical gels via the "bridging" of neighboring colloidal clay platelets by the polymer, with reversible adsorption of polymer segments onto the clay surface providing a short-range attractive force. As the flow disrupts this transient network, coupling between composition and stress leads to the formation of a macroscopic domain pattern, while the clay platelets orient with their surface normal parallel to the direction of vorticity. We discuss the shear-induced structure, steady-shear rheology, and oscillatory-shear response of these dynamic networks, and we offer a physical explanation for the mesoscale shear response. In contrast to flow-induced "banding" transitions, no stress plateau is observed in the region where macroscopic phase separation occurs. The observed platelet orientation is different from that reported for polymer-melt clay nanocomposites, which we attribute to effects associated with macroscopic phase separation under shear flow.     

Understanding and controlling the structure of polypropylene/layered silicate nanocomposites

The miscibility and structure in polypropylene/layered silicate nanocomposites is systematically investigated utilizing a maleic-anhydride grafted polypropylene with a low degree of functionalization acting as the compatibilizer. The morphology of the hybrids can be modified from phase separated to almost completely exfoliated in a controlled way by varying the ratio α of the compatibilizer to the organophilized clay; this ratio α is found to be the most important parameter in determining the final structure whereas exfoliated structures can be obtained for α values of 9 or higher. Furthermore, utilization of a “masterbatch” procedure can enhance the degree of exfoliation even for smaller values of α; in that case, polypropylene is essentially mixed with the already dispersed “hairy” platelets. Investigation of the thermal stability of the micro- and nanocomposites shows that high degree of exfoliation is vital in increasing the temperature that the polymer starts to degrade. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 2683–2695, 2008     

Fire properties of styrenic polymer-clay nanocomposites based on an oligomerically-modified clay

An oligomerically-modified clay has been used to fabricate nanocomposites with styrenic polymers, such as polystyrene, high-impacted polystyrene, poly(styrene-co-acrylonitrile) and acrylonitrile-butadiene-styrene by melt blending. The clay dispersion was evaluated by X-ray diffraction and bright field transmission electron microscopy. All of the nanocomposites have a mixed delaminated/intercalated structure. The fire properties of nanocomposites were evaluated by cone calorimetry a nd the mechanical properties were also evaluated.     

Mechanical properties of polyamide-12 layered silicate nanocomposites and their relations with structure

The mechanical properties of polyamide-12/Cloisite 30B (PA12/C30B) nanocomposites prepared by melt compounding were studied as a function of clay volume fraction φ under various processing conditions. All measured mechanical characteristics, Young's modulus, yield stress, strain at break and stress at break, exhibit a transition at φ_p1%, identified with a percolation threshold. Also, the linear and non-linear mechanical properties appeared to depend on the degree of exfoliation of the structure, which can be tuned by the processing conditions. The three-phase Ji's theoretical model was used to predict Young's modulus as a function of clay concentration, focusing on the influence of the degree of exfoliation. Experimental yield stress data were fitted to Pukanszky's model and discussed in terms of PA12/C30B interfacial adhesion.     

Ion transport in nanocomposites

Successive analysis of interface defect formation and its implications for the ionic conductivity was carried out for ionically conducting nanocomposites that hold much significance for technological applications. It was shown that the most efficient way to prepare such composites is through the use of nanosized particles. A review was made of the current state of research on inorganic composites and hybrid membrane materials that are already in use in alternative power engineering.     

Rheology of polymer layered silicate nanocomposites

Layered silicate based polymer nanocomposites have gained significant technological interest because of the recent commercialization of nylon 6 and polypropylene based materials. Aside from the natural interests in understanding and improving the processing of these hybrids, viscoelastic measurements have also proven to be a sensitive tool to probe the mesoscale structure and the strength of polymer–nanoparticle interactions.     

Fully exfoliated layered silicate epoxy nanocomposites

Fully exfoliated layered silicate epoxy nanocomposites are reported in this article. The processing route that resulted in these fully exfoliated layered silicate epoxies is based on a combination of high‐shear mixing in the presence of acetone and ultrasonication. Homomogeneous and random dispersion of the individual silicate nanolayers in the epoxy is confirmed through transmission electron microscopy images spanning low to high magnification as well as by X‐ray diffraction. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3981–3986, 2004     

Effect of chemical structure on combustion and thermal behaviour of polyurethane elastomer layered silicate nanocomposites

The effect of polyol molecular weight and functionality on nanodispersion of clay in PU/clay nanocomposites and the investigation of their thermal and combustion properties are reported and discussed. Lamellar elastomer polyurethane nanocomposites were synthesized using polyols with different molecular weight and functionality and according to these parameters they show several degrees of dispersion which affect their thermal and combustion behaviour. A barrier effect of clay layer is shown in TGA experiments by a delay of thermal degradation products release in nanocomposite materials compared to the virgin polymer; this barrier effect also leads to formation of char during combustion which lowers the peak of rate of heat release in cone calorimeter tests and eliminates fire-induced dripping of the nanocomposite sample during UL 94 test. However, in order to achieve non-burning behaviour nanocomposite technology must be combined with conventional flame retardant technology.     

Copolyester/layered silicate nanocomposites: The effect of the molecular size and molecular structure of the intercalant on the structure and viscoelastic properties of the nanocomposites

The preparation of poly(ethylene glycol‐co‐cyclohexane‐1,4‐dimethanol terephthalate)/layered silicate nanocomposites via a melt‐intercalation technique is reported. Layered silicates modified with different alkyl ammonium intercalants have been used for this purpose. A comparison is made between carefully chosen pairs of the nanocomposites, the choice depending on the cation‐exchange capacity or the intercalant concentration of the organically modified montmorillonite, to study the effects of the molecular size and molecular structure of the intercalant. The structure of the nanocomposites is characterized with wide‐angle X‐ray diffraction. The presence of well‐defined diffraction peaks and an observed increase in the interlayer spacing in the nanocomposites imply the formation of an intercalated hybrid. To investigate the viscoelastic behavior, these nanocomposites are also subjected to dynamic mechanical analysis. The dynamic mechanical properties show an increase in the storage modulus of the nanocomposites over the entire temperature range studied (except in the transition region from 68 to 78 °C) in comparison with that of the pristine polymer. The size of the intercalant molecule and the presence of functional groups capable of forming favorable interactions with the polymer govern the amount of polymer infiltrating the clay gallery space and control the increase in the modulus of the nanocomposite. The tan δ peak signifying the glass‐transition temperature shifts to lower temperatures in the nanocomposites. Interestingly, the nanocomposites show less damping than the pristine polymer. This behavior is understood in terms of the confinement of the polymer chains in the clay interlayer. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 3102–3113, 2003     

Thermal analysis of polymer layered silicate nanocomposites

It has been shown, for three different polymer layered silicate (PLS) nanocomposite systems, how differential scanning calorimetry (DSC) can identify the different reactions of homopolymerisation and of crosslinking that occur in the intra- and extra-gallery regions of these nanocomposites, respectively, and hence how DSC can be used to assess the cure conditions for optimising their nanostructure. The PLS nanocomposites are based upon: (i) diglycidyl ether of bisphenol-A (DGEBA) cured with a polyoxypropylene diamine; (ii) DGEBA cured with an –NH₂ terminated hyperbranched polymer (HBP); and (iii) tri-glycidyl p-amino phenol (TGAP) cured with a diamine. In each case, the existence of both intra- and extra-gallery reactions in the DSC cure curves, and whether they occur simultaneously or sequentially, and in what order, are identified and correlated with the nanostructure as observed by small angle X-ray scattering and transmission electron microscopy. In particular, it is shown that the intra-gallery reaction must precede the extra-gallery for significant exfoliation to occur. In accordance with this scenario, the TGAP/diamine system displays the greatest degree of exfoliation, the DGEBA/diamine system the least, with the DGEBA/HBP system intermediate. For those systems in which significant exfoliation occurs, the DSC cure curves also allow the optimum cure conditions, such as the isothermal cure temperature, to be determined.     

Electric-field-enhanced transport in polyacrylamide hydrogel nanocomposites

Electroosmotic pumping through uncharged hydrogels can be achieved by embedding the polymer network with charged colloidal inclusions. Matos et al. [M.A. Matos, L.R. White, R.D. Tilton, J. Colloid Interface Sci. 300 (2006) 429-436], recently used the concept to enhance the diffusion-limited flux of uncharged molecules across polyacrylamide hydrogel membranes for the purpose of improving the performance of biosensors. This paper seeks to link their reported macroscale diagnostics to physicochemical characteristics of the composite microstructure. The experiments are characterized by a Debye screening length that is much larger than the radius of the silica nanoinclusions and the Brinkman screening length of the polymer skeleton. Accordingly, closed-form expressions for the incremental pore mobility are derived, and these are evaluated by comparison with numerically exact solutions of the full electrokinetic model. A mathematical model for the bulk electroosmotically enhanced tracer flux is proposed, which is combined with the electrokinetic model to ascertain the electroosmotic pumping velocity from measured flux enhancements. Because the experiments are performed with a known current density, but unknown bulk conductivity and electric field strength, theoretical estimates of the bulk electrical conductivity are adopted. These account for nanoparticle polarization, added counterions, and non-specific adsorption. Theoretical predictions of the flux enhancement, achieved without any fitting parameters, are within a factor of two of the experiments. Alternatively, if the Brinkman screening length of the polymer skeleton is treated as a fitting parameter, then the best-fit values are bounded by the range 0.9-1.6 nm, depending on the inclusion size and volume fraction. Independent pressure-driven flow experiments reported in the literature for polyacrylamide gels without inclusions suggest 0.4 or 0.8 nm. The comparison can be improved by allowing for hindered ion migration, while uncertainties regarding the inclusion surface charge are demonstrated to have a negligible influence on the electroosmotic flow. Finally, and perhaps most importantly, anomalous variations in the flux enhancement with particle size and volume fraction can be rationalized at present only by acknowledging that particle-particle and particle-polymer interactions increase the effective permeability of the hydrogel skeleton. This bears similarities to the increase in polymer free volume that accompanies the addition of silica nanoparticles to certain polymeric membranes.     

Influence of the layered silicate type on the structure, morphology and properties of cellulose acetate nanocomposites

This paper deals with the effect of different montmorillonite source clays, including pristine and organophilic montmorillonites, on the structure, morphology and properties of cellulose acetate (CA)/clay nanocomposites. In this study, the nanocomposites were prepared by melt extrusion in the presence of the environmentally friendly triethyl citrate plasticizer. The structure and morphology of the materials were analysed by X-ray diffraction and scattering (SAXS), X-ray microtomography and energy filtered transmission electron microscopy (EFTEM). SAXS and EFTEM results indicated that the nanocomposite morphologies were made up of tactoids together with exfoliated clay platelets in different proportions depending on the clay type. It can be concluded that well distributed clay tactoids and platelets can be achieved in CA nanocomposites prepared by melt extrusion and consequently property improvements can be found by using pristine or organophilic clays. In this case, the addition of a plasticizer, able to intercalate in the clay gallery, seems to be sufficient to promote the clay delamination mechanism under shearing inside the cellulose acetate matrix.     

Mixed protonic-electronic conduction and dielectric response in layered vanadyl phosphate nanocomposites

The layered vanadyl phosphate, VOPO(4)2H(2)O, is employed to prepare nanosized conducting polypyrrole by redox intercalation method. Transport and dielectric properties of various compositions have been investigated by impedance technique over a temperature range of 300-120 K. Grain boundary conductivity is larger than the bulk conductivity. The conductivity reveals a discontinuity at about 212-235 K. The conductivity is predominantly ionic at high temperature and electronic at low temperature. The dielectric spectra reveal a peak in the frequency range up to 2 MHz for higher concentration of intercalated polypyrrole. The activation energy of conductivity relaxation is different from that of total conductivity derived from the impedance plot.     

Thermo-oxidative stability of polypropylene/layered silicate nanocomposites

Several series of experiments were carried out to check the effect of components on the stability of PP/layered silicate nanocomposites. The amount of organophilic montmorillonite (OMMT) changed between 0 and 6, while that of maleated polypropylene (MAPP) between 0 and 50 vol%. The composites were prepared in an internal mixer at 190 °C. Mixing speed and time were changed to study the effect of processing conditions on stability. The structure of the samples was characterised by various methods, while stability by the induction time of oxidation (OIT), the onset temperature of degradation (OOT) and by colour. Contrary to numerous claims published in the literature, which indicate the positive effect of layered silicates on the stability of polymer nanocomposites, our results clearly proved that both OMMT and MAPP accelerate degradation during processing and deteriorate the properties of PP composites. Residual stability decreases drastically with increasing amounts of both components, chain scission leads to the decrease of viscosity and to inferior strength and deformability. In spite of expectations, the effect of the components is independent of each other. Discoloration is caused mainly by the inherent colour of the filler and it decreases with increasing exfoliation. The most probable reason for decreased stability is the reaction of the components with the stabilisers, but this explanation needs further verification. Processing conditions influence degradation considerably, increasing shear rate and longer residence times lead to more pronounced degradation. The basic stabilization of commercial grade polypropylenes is insufficient to protect the polymer against degradation and without additional stabilization processing under normal conditions results in products with inferior quality.     

Effects of production parameters on the structure of resol type phenolic resin/layered silicate nanocomposites

Polymer/layered silicate nanocomposites belong to one of the most promising group of materials of the past few decades and most probably for the near future. Following the pioneering works of Toyota Research Group in the 1980s, the interest on these materials increased rapidly and research is now being carried out world wide, using all kinds of polymers as base material.In this present study, the aim was to investigate the effects of several different production parameters; on the morphology of resol type phenol formaldehyde based layered silicate nanocomposites produced by mixing and casting. For this purpose; two different liquid resol type phenolic resins (PF76 and PF76TD), two different curing methods (heat cure route and acid cure route), two different montmorillonite clays (unmodified Cloisite Na+ and modified Rheospan), two different clay sources (Wyoming-USA and Tokat-Turkey), and five different clay amounts (0.5%, 1%, 1.5%, 3%, 10%) were used.XRD, SEM, TEM analyses and mechanical tests indicated that resol type phenolic resins lead to better structures when they were modified with ethylene glycol and cured by the use of an acidic curing agent. It was also observed that use of modified clay with no more than 1.5 wt% in the phenolic matrix lead to certain degree of exfoliation consequently better structure and higher mechanical performance.     

Free volume and mass transport in polymer nanocomposites

This review relates the free volume properties and the morphology to the mass transport coefficients of polymer nanocomposites. Direct, utilising the method of Positron Annihilation Life-time Spectroscopy (PALS), or indirect measurements of the free volume in the nanocomposites are discussed and the influence of spherical or anisometric nanoparticles on its properties is examined.     

Polyolefin/layered silicate nanocomposites with functional compatibilizers

Polymer nanocomposites containing layered silicates have been considered as a new generation of composite materials due to their expected unique properties attributed to the high aspect ratio of the inorganic platelets. Nevertheless, addition of layered silicates to polyolefins mostly results in phase separated systems because of the incompatibility of the silicates with the non-polar polyolefins. Functional compatibilizers are required to enhance the interactions and alter the structure from phase separated micro-composites to intercalated and exfoliated nanocomposites. Commercial macromolecular compatibilizers (mainly maleic-anhydride-functionalized polyolefins) are most commonly used to improve the interfacial bonding between the fillers and the polymers whereas specifically synthesized functional homopolymers or copolymers have been utilized as well. In this article, we are reviewing a number of investigations, which studied the influence on the composite structure of various parameters like the compatilizer to inorganic ratio, the type and content of the functional groups and the molecular weight of the functional additive, the miscibility between the matrix polymer and the compatibilizer, the kind of surfactants modifying the inorganic surface, the processing conditions, etc. The most important results obtained utilizing maleic-anhydride-functionalized polyolefins are discussed first, whereas a summary is presented then of the studies performed utilizing other functional oligomers/polymers. X-ray diffraction and transmission electron microscopy studies supported by rheology indicate that the most important factor controlling the structure and the properties is the ratio of functional additive to organoclay whereas the miscibility between the matrix polymer and the compatibilizer is a prerequisite.