Comparison of solution-blending and melt-intercalation for the preparation of poly(ethylene-co-acrylic acid)/organoclay nanocomposites

Ethylene-acrylic acid copolymers (EAAs) and commercial montmorillonite clays organically modified with dimethyldihydrogenatedtallowammonium ions (Cloisite^® 15A and 20A) were used for the synthesis of nanocomposites by melt-compounding, static melting of polymer/clay mixtures and solution-intercalation in order to compare the effectiveness of these procedures and to shed light on the thermodynamics and the kinetics of the intercalation process. The preparation from solution was made by the use of several solvents, such as toluene, xylene, chloroform, etc., which were then removed from the hybrids by precipitation in different non-solvents or by evaporation. Particular attention was paid to the effect of the thermal treatments which are often used when processing the composites prepared from solution. X-ray diffraction (XRD) of the solution-blended composites showed that no intercalation of the EAAs inside the clay galleries can be achieved if solvent removal is made by precipitation in non-solvents or by room-temperature evaporation. On the contrary, intercalation was found to occur very rapidly (in less than 1 min) when both the hybrids prepared from solution and the mechanical blends of powdered components were melted in the absence of shear. Polymer intercalation was also found to occur, though with a lower rate, upon annealing the powder mixtures at temperatures lower than the EAA melting point. Microscopic observations made by polarized optical microscopy, scanning electron microscopy and transmission electron microscopy showed that the clay particles dispersion is appreciably lower for the composites prepared from solution, compared to those produced in the melt under shear flow conditions. The hybrids obtained by static melting of powder mixtures, on the other side, were expectedly found to comprise micron sized clay agglomerates, although intercalation was demonstrated also for these materials by XRD. The structure of the intercalated silicate layers stacks, characterized by an interlayer spacing of 4.0 nm, was shown to be independent of the preparation procedure and to correspond to thermodynamic equilibrium.     

Nanostructure vs. microstructure: Morphological and thermomechanical characterization of poly(l-lactic acid)/layered silicate hybrids

Nano- and micro-composites of poly(l-lactic acid) (PLLA) with various loadings of natural and hexadecylamine-modified montmorillonite were prepared by the solvent casting method to study the effect of nanostructure on the thermomechanical properties of the hybrid materials. The changes on structure and surface of montmorillonite, induced by the ion-exchange modification process, were characterized by X-ray diffraction (XRD) analysis and zeta-potential determination, while the morphology of the hybrids and the dispersion of the clay into the polymer matrix were examined by XRD, transmission electron microscopy and atomic force microscopy. The results showed that, although at low clay content exfoliation dominates, for filler loadings greater than 5 wt% both exfoliation and intercalation of the clay filler are observed. Thermal degradation studies of the materials produced using thermogravimetry revealed the introduction of a small amount of organo-modified silicate significantly improves their thermal stability. Differential scanning calorimetry showed the thermal behavior of the polymer matrix strongly depends on the nature and content of the silicate filler. Scanning electron microscopy of the deformed surfaces affirmed a different deformation process mechanism between the two types of composites.     

Catalytic activation of layered silicates for the synthesis of nanocomposite materials based on ultra-high molecular weight polyethylene

The effects of the structure of organomodified montmorillonite and the conditions of its catalytic activation by titanium and vanadium chlorides on the synthesis of nanocomposite materials based on ultra-high molecular weight polyethylene with an exfoliated structure by an in situ polymerization method were studied. It was shown that, with the use of organomodified montmorillonite with the interplanar spacing d₀₀₁ = 1.6–1.8 nm, in which the alkyl radicals of a modifier are arranged in parallel to the basal silicate surfaces, the catalyst is adsorbed only on the external surface of particle, and it does not penetrate into the interlayer space (in this case, the exfoliation of a filler does not occur). With the use of montmorillonite samples with d₀₀₁ > 2 nm with the packing of a modifier as paraffin-like mono- or bilayers, the catalyst is predominantly intercalated into the interlayer space of the layer silicate. As a result, in the course of polymerization, polyethylene is formed in the interlayer space of particles to facilitate the exfoliation of the filler in separate nanolayers. Conditions for the supporting of a catalyst onto organomodified montmorillonite, which prevent the transfer of the catalyst into solvent and the formation of a free polymer on the synthesis of nanocomposites under the conditions of suspension polymerization in n-heptane, were determined. The intercalation of a catalyst into the interlayer space of the particles of layered silicates and the exfoliation of filler particles in the course of the synthesis of composites were confirmed by X-ray diffraction analysis.     

Structure and morphology of HDPE-g-MA/organoclay nanocomposites: Effects of the preparation procedures

Nanocomposites comprising high density polyethylene (HDPE) or maleic anhydride-grafted HDPE (HDMA) as the host polymers and Cloisite^® 20A (20A) as the organoclay filler were prepared by melt-compounding, solution-blending and static annealing of polymer/clay powder mixtures. The dependence of their structure and morphology on the preparation conditions was studied by X-ray diffraction (XRD and SAXS), polarized optical microscopy (POM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). It was shown that intercalated nanocomposites based on HDPE or HDMA cannot be obtained by solution-blending, as long as solvent removal is made at room temperature. In fact, wide angle XRD patterns of solution blended composites are similar to those of mechanical blends of clay and polymer. However, as demonstrated by XRD and SAXS, fast intercalation or even complete delamination was obtained when the HDMA composites prepared from solution were annealed statically at temperatures higher than the polymer melting point. This implies that solution-blending causes efficient fragmentation of the clay agglomerates into thin tactoids (though unintercalated) homogeneously dispersed in the polymer matrix. This conclusion, supported by the finding that annealing mechanical blends of polymer and clay powders only leads to intercalated structures, was confirmed by TEM and SEM analyses. Morphology investigation revealed that, in contrast to melt-compounding, solution-blending followed by static annealing fails to produce significant orientation of clay platelets and polymer crystallites. However, repeated compression molding cycles were shown by XRD and SAXS to cause increasing levels of orientation of the platelets and the polymer matrix parallel to the sample flat surface.     

Synthesis and structure of poly(ε-caprolactone)/synthetic montmorillonite nano-intercalates

Bulk polymerisations of ε-caprolactone (CL) were conducted at 170 °C in the presence of catalytic traces of water and 10, 30 and 50 wt% of hydrated synthetic montmorillonite SOMASIF ME100 (M) without additional catalysts. In both cases a low molecular poly(ε-caprolactone) (PCL) was produced (M_w = 5360-22,432). As revealed by ¹H NMR and GPC analyses the montmorillonite present in the system induced both significantly higher lactone hydrolysis and polymer chain growth rates. Wide-angle X-ray scattering (WAXS) technique was applied to investigate the changes in clay stratification after swelling with monomer and after the polymerisation. The scattering peaks from clay (0 0 1) periodicity recorded for the silicate in dispersions and in the composites are shifted towards lower angles, which indicate an intercalation of CL as well as PCL in the galleries. Narrow intensity distribution of Bragg peaks recorded for both CL/M mixtures and resulting nano-intercalates testifies that the well ordered, layered structure of montmorillonite is retained in the silicate swollen with ε-caprolactone and after the polymerisation. The results suggest that PCL chains are flatly arranged onto each side of silicate platelet and they create pseudo-bilayers inside the silicate’s gallery.     

Synthesis and thermal behaviour of polyamide 6/bentonite/ammonium polyphosphate composites

In order to achieve acceptable levels of flame retardancy of polymers, phosphorus-based flame retardant (FR) additives at about 20-30% w/w are required which is too high for conventional synthetic fibres. To know whether more finely sized particles of conventional FRs with or without nanoclay are more effective at the same concentration, composites of PA6 with bentonite and ammonium polyphosphate (APP) have been prepared by melt processing in a twin-screw extruder. XRD peaks and TEM images of PA6/Org-bentonite composite show partially ordered intercalation and ordered exfoliation. Thermal analysis in He shows that thermal stability of PA6 nanocomposite has increased by 18 °C compared with pure PA6 during degradation after 425 °C but it has decreased by 100 °C on inclusion of APP in PA6/nanoclay composites. The char yield is increased by 20% in PA6/bentonite/APP composites. No effect on thermal stability or char yield is observed by reducing the particle size of APP.     

Properties of rubber filled with montmorillonite with various surface modifications

Layered silicate/natural rubber composites were prepared by direct polymer melt intercalation. Na‐montmorillonite Kunipia‐F and its organic derivates (organo‐clays) prepared by ion exchange were used as clay fillers. Silica (SiO₂) Ultrasil VN3, a filler commonly used in the rubber industry, was used in combination with clay fillers. The effect of clay or organo‐clay loading from 1 up to 10 phr without (0 phr) or with silica (15 phr) showed significant improvement of the tensile properties (stress at break, strain at break and modulus M100). Modification of montmorillonite by three alkylammonium cations with the same length of alkylammonium chain (18 carbons) and different structure resulted in altered reinforcing and plasticizing effects of the filler in composites with rubber matrix. Copyright © 2011 John Wiley & Sons, Ltd.     

Intercalated poly(vinylidene fluoride)/clay nanocomposites: Structure and properties

The preparation and characterization of melt‐intercalated poly(vinylidene fluoride) (PVDF)/clay nanocomposites are reported. Organophilic clay (clay treated with dimethyl dihydrogenated tallow quaternary ammonium chloride) was used for the nanocomposite preparation. The composites were characterized with X‐ray diffraction (XRD), differential scanning calorimetry (DSC), and dynamic mechanical analysis (DMA). XRD results indicated the intercalation of the polymer in the interlayer spacing. The incorporation of clay in PVDF resulted in the β form of PVDF. DSC nonisothermal curves showed an increase in the melting and crystallization temperatures along with a decrease in crystallinity. Isothermal crystallization studies show an enhanced rate of crystallization with the addition of clay. DMA indicated significant improvements in the storage modulus over a temperature range of ?100 to 150 °C. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 31–38, 2003     

Flammability and phase-transition studies of nylon 6/montmorillonite nanocomposites

Nylon 6 (PA6)/clay hybrids have been prepared using a direct melt intercalation technique by two processes. One is PA6 melt-mixing with modified clay, the other is PA6 melt-mixing with natural (Na⁺ base) clay using an ammonium salt bearing long alkyl chains as a polymer/clay reactive compatibilizer. Their structure and flammability properties are characterized by X-ray diffraction, transmission electron microscopy and cone calorimeter experiments. The results of the cone calorimeter experiments show that hybrids made by these two processes have a lower heat release rate peak and higher thermal stability than that of original PA6. Meanwhile, X-ray diffraction was used to investigate PA6/clay hybrids with various cooling histories from the melt, including medium-rate cooling (air cooling) and rapid cooling (water-quenched). In contrast to pure PA6 dominated by the α phase, the addition of clay silicate layers by these two methods favors the formation of the γ crystalline phase in PA6/clay hybrids. Flammability and phase-transition studies confirm that silicate layers added by these two methods have a similar nanoeffect and nanodispersion in the PA6 matrix.     

Nanoclay‐induced morphology development in chaotic mixing of immiscible polymers

This study investigated the role of layered silicate clay on morphology development in chaotic mixing of two immiscible polymers, polypropylene (PP) and polyamide 6 (PA6). The study showed that clay particles helped to produce droplets of much smaller size and with narrower size distribution due to their direct influence on the breakup of PP domains. In the experiments, a small quantity of organically modified layered silicate clay was initially mixed in PP and the mixture was blended with PA6 in a chaotic mixer. All morphological forms, such as lamellas, fibrils, and droplets were seen as in the case with no clay. The clay particles reduced interfacial tension between PP and PA6 phases. As a consequence, the PP domains sustained lamellar and fibrillar forms, and thin fibrils were formed. These thin fibrils in turn broke rapidly into smaller droplets. It was also found that a large fraction of clay particles migrated into PA6 phase and contained intercalated PA6 chains in their galleries. These results indicate that clay particles did not participate in compatibilization in this system. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 3638–3651, 2005     

Preparation and Barrier Properties of Chitosan-Layered Silicate Nanocomposite Films

Summary: In this study, chitosan nanocomposite films were prepared using a solvent-casting method by incorporation of an organically modified montmorillonite (Cloisite 10A). The effect of filler concentration on the water vapor permeability, oxygen permeability, mechanical and thermal properties of the composite films was evaluated. The structure of nanocomposites and the state of intercalation of the clay were characterized by XRD. The water vapor permeability of pure chitosan films was measured as a function of relative humidity (RH). It was found that the permeability value increased with an increase in RH. The water vapor and gas permeability values of the composite films decreased significantly with increasing filler concentration. Permeation data was fitted to various phenomenological models predicting the permeability of polymer systems filled with nanoclays as a function of clay concentration and aspect ratio of nanoplatelets. According to the XRD results, an increase in basal spacing was obtained with respect to pure clay for chitosan/clay nanocomposites. This demonstrated the formation of intercalated structure of clay in the polymer matrix. Tensile strength and elongation at break of the composites increased significantly with the addition of clay, however the thermal and color properties of the films were not much affected by the intercalation of clay into polymer matrix.     

Intercalation behavior of amino acids into Zn-Al-layered double hydroxide by calcination-rehydration reaction

The intercalation of amino acids for the Zn-Al-layered double hydroxide (LDH) has been investigated by the calcination-rehydration reaction at 298 K using mainly phenylalanine (Phe) as a guest amino acid. The Zn-Al oxide precursor prepared by the calcination of Zn-Al-carbonated LDH at 773 K for 2 h was used as the host material. The amount of Phe intercalated by the rehydration was remarkably influenced by the initial solution pH and reached ca. 2.7 times for anion exchange capacity (AEC) of the LDH at neutral and weak alkaline solutions, suggesting that Phe was intercalated as amphoteric ion form into the LDH interlayer. As Phe is intercalated for the LDH as monovalent anion in alkaline solution, the amount of Phe intercalated at pH 10.5 corresponded with AEC of the LDH. The solid products were found to have the expanded LDH structure, which confirmed that Phe was intercalated into the LDH interlayer as amphoteric ion or anion form. The basal spacing, d₀₀₃, of the Phe/LDH was 1.58 nm at pH 7.0 and 0.80 nm at pH 10.5; two kinds of expansion suggested for Phe in the interlayer space as vertical (pH 7.0) and horizontal (pH 10.5) orientations. The intercalation behavior of various amino acids for the LDH was also found to be greatly influenced by the feature of the amino acid side-chain, namely, its carbon-chain length, structure and physicochemical property. In particular, α-amino acids possessing a hydrophobic or negative-charged side-chain were preferentially intercalated for the LDH.     

Electrically conductive composites of polyethylene filled with polyamide particles coated with silver

New types of electrically conductive polymeric composites were prepared on a base of high-density polyethylene (HDPE) matrix filled with silver-coated polyamide (PA) particles. The electrical, mechanical and adhesive properties of those composites are reported in this paper. The percolation concentration of the filler within a matrix was found to be 4 vol.%. Composites filled with high filler content were highly electrically conductive; their electrical conductivity reached the value of 6.8 × 10² S cm⁻¹. Mechanical properties and rheology of these composites were discussed. The adhesive properties of the composites to metal sharply increased with an increase in the filler content.     

Structure analysis of intercalated layer silicates: combination of molecular simulations and experiment

Na(+)-montmorillonite type Wyoming, cloisite Na(+) from Southern Clay Products, Inc., was intercalated (i) with octadecylammonium cations and subsequently intercalated with octadecylamine molecules, (ii) with dodecylamine molecules, and (iii) with octylamine molecules to determine the applicability of these intercalates for nanocomposite materials on the base of polymer/clay. The structures were determined on the basis of a combination of results from X-ray diffraction and molecular simulations. The calculated values of basal spacings are in good agreement with experimental basal spacings when experimental samples were prepared. The interlayer space of intercalated montmorillonite shows a monolayer or bilayer arrangement of alkyl chains in dependence on the concentration of the intercalation solution. The values of the total sublimation energy, interaction energy, and exfoliation energy were calculated for all investigated samples. Low values of exfoliation energies lead to better exfoliation of intercalated silicate layers and this material appears suitable for use as a precursor for polymer/clay nanocomposites. The values of exfoliation energy for the investigated samples show that montmorillonite intercalated with dodecylamine or octadecylamine molecules is suitable for exfoliation of silicate layers.     

Preparation and crystallization behaviour of PP/PP-g-MAH/Org-MMT nanocomposite

The melt-direct intercalation method was employed to prepare polypropylene (PP)/maleic anhydride grafted polypropylene (PP-g-MAH)/organic-montmorillonite (Org-MMT), X-ray diffractometer was used to investigate the intercalation effect and crystallite size in composites and TEM micrograph to observe the dispersion of Org-MMT interlayers in polypropylene. The results showed that by introducing maleated polypropylene in PP/Org-MMT composite, macromolecule segments had intercalated into interlayer space of Org-MMT. As a result, Org-MMT interlayers were dispersed evenly in polypropylene and PP/PP-g-MAH/Org-MMT nanocomposite was synthesized. The crystallite size of nanocomposite perpendicular to the crystalline plane such as (0 4 0), (1 3 0), (1 1 1), (0 4 1) is smaller than that of pristine PP, which indicated that the crystallite size of PP in nanocomposite can be diminished by adding PP-g-MAH and Org-MMT in PP. Moreover, the nonisothermal crystallization kinetics of PP and PP/PP-g-MAH/Org-MMT nanocomposite was investigated by differential scanning calorimetry (DSC) with various cooling rates. The Avrami analysis modified by Jeziorny, Ozawa method and a method developed by Liu were employed to describe the nonisothermal crystallization process of these samples. The difference in the exponent n between PP and nanocomposite, indicated that nonisothermal kinetic crystallization corresponded to tridimensional growth with heterogeneous nucleation. The values of half-time, Z_c, F(T) and K(T) showed that the crystallization rate of composites was faster than that of PP at a given cooling rate.     

Homoionic inorganic montmorillonites as fillers for polyamide 6 nanocomposites

The homoionic montmorillonites Ca-MMT, Mg-MMT, Ba-MMT and Ca-MMT intercalated with ε-caprolactam - Ca-MMT·CL were prepared from commercial Na-MMT and characterized by WAXS and TGA. They were used as fillers for nanocomposites of polyamide 6 synthesized either by anionic polymerization of ε-caprolactam (monomer casting) or by melt blending. WAXS analysis showed that the intercalation of MMT by the polyamide was complete for all nanocomposites, with only a very small fraction of exfoliated platelets being detected by TEM. The decrease in the number of layers in the MMT tactoids suggests that tactoid splitting was lower for the blended nanocomposites than for the polymerized ones. Both the rate of polymerization and the polyamide yield in the nanocomposites were comparable to those of an unfilled system. The MMT fillers, the density of which was more than twice that of the ε-caprolactam in which they were suspended, sedimented during the first stage of polymerization. TGA was used to determine the degree of sedimentation at various levels of the resulting mold. In line with the coordination of polyamide chains to the surface cations of MMT particles, the sedimentation level increased in the following sequence: Mg-MMT < Ba-MMT < Ca-MMT·CL << Na-MMT. Ca-MMT was found to be the only non-sedimenting filler suitable for use in the synthesis of polyamide nanocomposites by either monomer casting or the use of reactive injection molding (RIM) technologies.     

Long‐lived layered silicates‐immobilized 2,6‐bis(imino)pyridyl iron (II) catalysts for hybrid polyethylene nanocomposites by in situ polymerization: Effect of aryl ligand and silicate modification

Heterogeneous‐layered silicate‐immobilized 2,6‐bis(imino)pyridyl iron (II) dichloride/MMAO catalysts, in which the active polymerization species are intercalated within sodium‐ and organomodified‐layered silicate galleries, were prepared for producing hybrid exfoliated polyethylene (PE) nanocomposites by means of in situ polymerization. The inorganic filler was first treated with modified‐methylaluminoxane (MMAO) to produce a supported cocatalyst: MMAO reacts with silicates replacing most of the organic surfactant, thus modifying the original crystallographic clay order. MMAO anchored to the nanoclay was able to activate polymerization iron complexes initiating the polymer growth directly from the filler lamellae interlayer. The polymerization mechanism taking place in between the montmorillonite lamellae separates the layers, thus promoting deagglomeration and effective clay dispersion. Transmission electron microscopy revealed that in situ polymerization by catalytically active iron complexes intercalated within the lower organomodified clay led to fine dispersion and high exfoliation extent. The intercalated clay catalysts displayed a longer polymerization life‐time and brought about ethylene polymerization more efficiently than analogous homogeneous systems. PEs having higher molecular masses were obtained. These benefits resulted to be dependent more on the filler nature than on the ligand environment around the iron metal center and the experimental synthetic route. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 548–564, 2009     

Effect of clay modification on the structure and mechanical properties of polyamide-6 nanocomposites

Polyamide-6 nanocomposites were prepared from a new phosphonium organoclay obtained at pilot scale in supercritical carbon dioxide (scCO₂) and a commercially available ammonium modified-silicate. The composites were homogenised by twin-screw extrusion, then specimens for testing were prepared by injection moulding. The clay content of the composites was varied from 0 to 7 vol.% in 7 steps. The clays were characterised in detail; they differed in their surface coverage and gallery structure, while their particle size was similar and their surface energy differed only slightly. X-ray diffraction, electronic microscopy and rheology were used for the characterisation of composite structure. Different gallery structure of the clays led to dissimilar extent of exfoliation. The phosphonium organoclay exfoliated better in PA than the silicate treated with the ammonium salt in spite of its smaller surface coverage. The nanocomposites showed the usual complex structure: besides individual platelets and intercalated stacks, large particles were also present and the development of a silicate network could be shown at large clay contents. Quantitative determination of the extent of reinforcement revealed two determining factors: contact surface and strength of interaction. The first increases with exfoliation, but the latter decreases as an effect of organophilisation. The extent of exfoliation was also estimated quantitatively, and the calculation confirmed the results of qualitative evaluation showing larger extent of exfoliation for the scCO₂-prepared phosphonium clay.     

Preparation of an anionic azo pigment-pillared layered double hydroxide and the thermo- and photostability of the resulting intercalated material

A large anionic pigment has been intercalated into a layered double hydroxide (LDH) host by ion-exchange of an Mg/Al LDH-nitrate precursor with a solution of C.I. Pigment Red 48:2 (the calcium salt of 4-((5-chloro-4-methyl-2-sulfophenyl)azo)-3-hydroxy-2-naphthalene-carboxylic acid), in ethane-1,2-diol. After intercalation of the pigment, the interlayer distance in the LDH increases from 0.86 to 1.72 nm. Infrared spectra and TG-DTA curves reveal the presence of a complex system of supramolecular host-guest interactions. The UV-visible diffuse reflectance spectra of C.I. Pigment Red 48:2 show marked changes after heating at 200 °C and above, whereas there are no significant changes in the spectra of the intercalated pigment after heating at temperatures up to 300 °C, showing that the thermostability is markedly enhanced by intercalation in the LDH host. The pigment-intercalated LDHs exhibits much higher photostability to UV light than the pristine pigment, in the case of both the pure solids and their composites with polypropylene, as shown by measurement of CIE 1976 L^*a^*b^* color difference (ΔE) values.     

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