The effect of a semi‐industrial masterbatch process on the carbon nanotube agglomerates and its influence in the properties of thermoplastic carbon nanotube composites

This study details an industrial process to prepare polypropylene (PP) composites reinforced with different loadings (0.5–10wt.%) of carbon nanotubes (CNTs) from a direct dilution of a masterbatch produced by an optimized extrusion compounding process. The work demonstrates how the anisotropy in the distribution of CNTs can have a positive effect on the electrical conductivity and fracture toughness of the resulting composites. The composite with the highest loading of CNTs had an electrical conductivity of 10^?2 S/m comparable with those reported in the available literature. The composites showed anisotropy in their properties that seems to be caused by the non‐homogeneous distribution of the agglomerates produced by the orientation of the flow direction during the injection process. The composites produced in this work exhibited a fracture toughness up to 55% higher than neat PP and failed by polymer ductile tearing. It was found that the CNT agglomerates distributed throughout the matrix increased the toughness of PP by promoting plastic deformation of the matrix during the fracture process and by a slight load transfer between the polymer matrix and the CNTs of the agglomerates. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55 , 189–197     

Structural and morphological studies on the deformation behavior of polypropylene/multi‐walled carbon nanotubes nanocomposites prepared through ultrasound‐assisted melt extrusion process

Structural and morphological behavior under stress–strain of polypropylene/multi‐walled carbon nanotubes (PP/MWCNTs) nanocomposites prepared through ultrasound‐assisted melt extrusion process was studied by means of optical microscopy, scanning electron microscopy, transmission electron microscopy, Raman spectroscopy, small angle X‐ray scattering (SAXS), and wide angle X‐ray scattering (WAXS). A high ductile behavior was observed in the PP/MWCNT nanocomposites with low concentration of MWCNTs. This was related to an energy‐dissipating mechanism, achieved by the formation of an ordered PP‐CNTs interphase zone and crystal oriented structure in the undeformed samples. Different strain‐induced‐phase transformations were observed by ex situ SAXS/WAXS, characterizing the different stages of structure development during the deformation of PP and PP/MWCNTs nanocomposites. The high concentration of CNTs reduced the strain behavior of PP due to the agglomeration of nanoparticles. A structural pathway relating the deformation‐induced phase transitions and the dissipation energy mechanism in the PP/MWCNTs nanocomposites at low concentration of nanoparticles was proposed. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 475–491     

Preparation and characterization of multiwalled carbon nanotube dispersions in polypropylene: Melt mixing versus solid‐state shear pulverization

Dispersions of multiwalled carbon nanotubes (MWNT) in polypropylene (PP) were prepared via conventional melt batch mixing and solid‐state shear pulverization. The properties and structure of each system were assessed via linear viscoelasticity, electrical conductivity, PP crystallization kinetics, dynamic mechanical analysis, scanning electron microscopy, and small angle X‐ray scattering. Increasing either the duration or the intensity of melt mixing leads to higher degrees of dispersion of MWNT in PP, although at the cost of substantial melt degradation of PP for long mixing times. Samples prepared by pulverization exhibit faster crystallization kinetics and higher mechanical stiffness than the melt blended samples, but in contrast show no measurable low frequency elastic plateau in melt rheology, and lower electrical conductivity than melt‐mixed samples. X‐ray scattering demonstrates that neither sample has uniform dispersion down to the single MWNT level. The results illustrate that subtle differences in the size and distribution of nanotube clusters lead to differences in the nanotube networks with strong impact on bulk properties. The results also highlight distinctions between conductive networks and load transfer networks and demonstrate that a complete and comparative picture of dispersion cannot be determined by simple indirect property measurements. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1426–1436, 2009     

The influence of wood flour and compatibilizer (<Emphasis Type="Italic">m</Emphasis>-TMI-<Emphasis Type="Italic">g</Emphasis>-PP) on crystallization and melting behavior of polypropylene

Wood flour/polypropylene composites (WPC) were prepared by melt extruding with different wood flour (WF) loadings. The non-isothermal crystallization and melting was studied with different WF loadings, for W40P60 and W40P60M6, the melting was investigated after non-isothermal and isothermal crystalline. Comparing with neat polypropylene, the melting behavior of the composites, both non-isothermally and isothermally, was investigated by differential scanning calorimetry (DSC). The results showed that WF was an effective heterogeneous nucleating agent, as evidenced by an increase in the crystallization temperature and the crystallinity for melt crystallization of PP with increasing WF content. For the non-isothermal samples, the origins of the double melting behaviors were discussed, based on the DSC results of PP. The XRD measurements confirmed that no crystalline transition existed during the non-isothermal crystallization process. With m-TMI-g-PP adding, due to compatibilization phenomenon were probably responsible for decreasing T _m, X _c. In the DSC scan after isothermal crystallization process, the single melting behaviors were found and each melting endotherm had a different origin.     

Effect of dispersion and selective localization of carbon nanotubes on rheology and electrical conductivity of polyamide 6 (PA6), Polypropylene (PP), and PA6/PP nanocomposites

Nanocomposites were prepared by adding 1–3 vol % multiwalled carbon nanotubes (MWCNTs) to polyamide 6 (PA6), polypropylene (PP), and their co‐continuous blends of 60/40 and 50/50 volume compositions. Because of the good interaction and interfacial adhesion to the PA6, nanotubes were disentangled and distributed evenly through nanocomposites containing PA6. In contrast, lack of active interactions between the matrix and the CNTs resulted in poor tube dispersion in PP. These observations were then verified by studying the rheology and electrical conductivity of their respective nanocomposites. Absence of percolated CNT clusters and possible wrapping of the tubes by PA6 resulted in low electrical conductivity of PA6/CNT nanocomposites. On the other hand, despite the weak dispersion of the tubes, electrical conductivities of PP/CNT nanocomposites were much higher than all other counterparts. This could be the result of good three‐dimensional distribution of the agglomerated bundles and secondary aggregation of tubes in PP. Adding CNTs to blends of PA6/PP (60/40 and 50/50) resulted in almost full localization of carbon nanotubes in PA6, leading to their higher effective concentration. At the same CNT loadings, the blend nanocomposites had three to seven orders of magnitude higher electrical conductivity than pure PA6. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 368–378     

Solid-state shear pulverization as effective treatment for dispersing lignocellulose nanofibers in polypropylene composites

Lignocellulose nanofibers (LCNFs) were prepared by the wet-disk milling of wood flour and were subsequently used as a reinforcing filler for a polypropylene (PP) polymer matrix. The specific surface area and the smallest fiber width of the LCNFs were found to be 106 m²/g and 20 nm, respectively. Solid-state shear pulverization (SSSP) using a batch-type kneader was performed at a temperature lower than the PP melting point in order to improve the dispersion of the LCNFs in the PP matrix, which also contained 5 wt% maleic anhydride-grafted PP. The SSSP treatment improved LCNF dispersion; this was determined through optical and scanning electron microscopy observations. The improvement in LCNF dispersion after the SSSP treatment increased the Young’s moduli, yield strengths, and toughnesses of the resulting composites. The composites showed higher Young’s moduli and yield strengths that those of the neat PP matrix; this was true in the case of both the tensile and the bending tests. However, the impact strengths of the composites were not significantly different from that of the neat matrix. Finally, the crystallization rate of the PP matrix also increased with the increase in LCNF dispersion.     

Morphological and mechanical properties of carbon nanotube/polymer composites via melt compounding

The mechanical properties and morphology of multiwall carbon nanotube (MWNT)/polypropylene (PP) nanocomposites were studied as a function of nanotube orientation and concentration. Through melt mixing followed by melt drawing, using a twin screw mini‐extruder with a specially designed winding apparatus, the dispersion and orientation of MWNTs was optimized in PP. Tensile tests showed a 32% increase in toughness for a 0.25 wt % MWNT in PP (over pure PP). Moreover, modulus increased by 138% with 0.25 wt % MWNTs. Transmission electron microscopy and scanning electron microscopy demonstrated qualitative nanotube dispersion and orientation. Wide angle X‐ray diffraction was used to study crystal morphology and orientation by calculating the Herman's orientation factor for the composites as function of nanotube loading and orientation. The addition of nanotubes to oriented samples causes the crystalline morphology to shift from α and mesophase to only α phase. Furthermore, the addition of nanotubes (without orientation) was found to cause isotropization of the PP crystal, and drawing was shown to improve crystal orientation through the orientation factor. In addition, differential scanning caloriometry qualitatively revealed little change in overall crystallinity. In conclusion, this work has shown that melt mixing coupled with melt drawing has yielded MWNT/PP composites with a unique combination of strength and toughness suitable for advanced fiber applications, such as smart fibers and high‐performance fabrics. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 864–878, 2006     

Electrical and melt rheological characterization of PC and co‐continuous PC/SAN blends filled with CNTs: Relationship between melt‐mixing parameters,filler dispersion,and filler aspect ratio

Electrical and melt rheological properties of melt‐mixed polycarbonate (PC) and co‐continuous PC/poly(styrene–acrylonitrile) (SAN) blends with carbon nanotubes (CNTs) are investigated. Using two sets of mixing parameters, different states of filler dispersion are obtained. With increasing CNT dispersion, an increase in electrical resistivity near the percolation threshold of PC–CNT composites and (PC + CNT)/SAN blends is observed. This suggests that the higher mixing energies required for better dispersion also result in a more severe reduction of the CNT aspect ratio; this effect was proven by CNT length measurements. Melt rheological studies show higher reinforcing effects for composites with worse dispersion. The Eilers equation, describing the melt viscosity as function of filler content, was used to fit the data and to obtain information about an apparent aspect ratio change, which was in accordance with measured CNT length reduction. Such fitting could be also transferred to the blends and serves for a qualitatively based discussion. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2018 , 56, 79–88     

Comparison of the effect of mica and talc and chemical coupling on the rheology,morphology, and mechanical properties of polypropylene composites

The effect of filler types of mica and talc on the oscillatory shear rheological properties, mechanical performance, and morphology of the chemically coupled polypropylene composites is studied in this work. The Maleic Anhydride grafted Polypropylene (MAPP) was used as an adhesion promoter for coupling mineral particles with the polypropylene matrix. The samples were prepared by a co‐rotating, L/D = 40, 25 mm twin screw extruder. The tensile tests carried out on the injection molded samples showed a reinforcing effect of talc up to 20 wt% on the Polypropylene (PP). The tensile strength of PP‐mica composites showed a slight decrease at all percentages of mica. The effect of chemical coupling by using MAPP on the tensile strength was more pronounced in increasing the tensile strength for PP‐mica than PP‐talc composites. The complex viscosity curve of pure PP and the composites, showed a Newtonian plateau (η₀) up to 30 wt% at low frequency terminal zone. By increasing the filler content to 40 and 50 wt%, the complex viscosity at very low shear rates sharply increased and showed yield behavior that can be due to the formation of filler particles networks in the melt. At the optimum amount of coupling agent, a minimum in cross over frequency curve against MAPP content is observed. The optimum amount of coupling agent for PP‐talc composites is about 1.5%, and about 3% for PP‐mica formulations. The analysis of viscosity behavior at power‐law high region, revealed the more shear thinning effect of mica than talc on the PP matrix resin. Copyright © 2009 John Wiley & Sons, Ltd.     

Influence of organo-clay on electrical and mechanical properties of PP/MWCNT/OC nanocomposites

The electrical, thermal and mechanical properties of nanocomposites, based on polypropylene (PP) filled by multi-walled carbon nanotubes (MWCNTs) and organo-clay (OC), were studied with the purpose of finding out the effect of OC on the microstructure of MWCNTs dispersion and PP/MWCNT/OC composites. It was found that addition of organo-clay nanoparticles improved nanotube dispersion and enhanced electrical properties of PP/MWCNT nanocomposites. Addition of organo-clay (MWCNT/OC ratio was 1/1) reduced the percolation threshold of PP/MWCNT nanocomposites from ?_c = 0.95 vol.% to ?_c = 0.68 vol.% of carbon nanotubes, while the level of conductivity became 2–4 orders of magnitude higher. The DSC and DMA analyses have shown that the influence of organo-clay on the thermal and mechanical properties of material was not significant in composites with both fillers as compared to PP/OC. Such an effect can be caused by stronger interaction of OC with carbon nanotubes than with polymer matrix.     

Thermal curing behavior of MWCNT modified vinyl ester‐polyester resin suspensions prepared with 3‐roll milling technique

This study aims to investigate the curing behavior of a vinyl ester‐polyester resin suspensions containing 0.3 wt % of multiwalled carbon nanotubes with and without amine functional groups (MWCNTs and MWCNT‐NH₂). For this purpose, various analytical techniques, including Differential Scanning Calorimetry (DSC), Fourier infrared spectroscopy (FTIR), Raman Spectroscopy, and Thermo Gravimetric Analyzer (TGA) were conducted. The resin suspensions with carbon nanotubes (CNTs) were prepared via 3‐roll milling technique. DSC measurements showed that resin suspensions containing CNTs exhibited higher heat of cure (Q), besides lower activation energy (E_a) when compared with neat resin. For the sake of simplicity of interpretation, FTIR investigations were performed on neat vinyl ester resin suspensions containing the same amount of CNTs as resin. As a result, the individual fractional conversion rates of styrene and vinyl ester were interestingly found to be altered dependent on MWCNTs and MWCNT‐NH₂. The findings obtained from RS measurements of the cured samples are highly proportional to those obtained from FTIR measurements. TGA measurements revealed that CNT modified nanocomposites have higher activation energy of degradation (E_d) compared with the cured polymer. The findings obtained revealed that CNTs with and without amine functional groups alter overall thermal curing response of the surrounding matrix resin, which may probably impart distinctive characteristics to mechanical behavior of the corresponding nanocomposites achieved. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1511–1522, 2009     

Poly(lactic acid)-based polymer composites with high electric and thermal conductivity and their characterization

Electrically and thermally conductive polymer composites on the basis of biodegradable poly(lactic acid) (PLA) were developed and studied in this work. Pristine single-walled carbon nanotubes (CNTs) and powder of natural graphite (G) were used as fillers in polymer composites. PLA-based composites were prepared by melt-compounding method. The volume resistivity of PLA/CNT composites can be changed by more than ten orders of magnitude compared to that for neat PLA. The thermal conductivity of PLA/G composites can be changed from 0.193 W⋅m⁻¹⋅K⁻¹ (neat PLA) up to 2.73 W⋅m⁻¹⋅K⁻¹. Loading small quantity of CNTs into PLA/G composites increases the thermal conductivity not less than by 40% of magnitude. Besides, all developed PLA-based composites are suitable for processing by injection molding, extrusion or additive manufacturing technology (3D printing).     

Effect of nanosized carbon black on thermal stability and flame retardancy of polypropylene/carbon nanotubes nanocomposites

Nanosized carbon black (CB) was introduced into polypropylene/carbon nanotubes (PP/CNTs) nanocomposites to investigate the effect of multi‐component nanofillers on the thermal stability and flammability properties of PP. The obtained ternary nanocomposites displayed dramatically improved thermal stability compared with neat PP and PP/CNTs nanocomposites. Moreover, the flame retardancy of resultant nanocomposites was greatly improved with a significant reduction in peak heat release rate and increase of limited oxygen index value, and it was strongly dependent on the content of CB. This enhanced effect was attributed mainly to the formation of good carbon protective layers by CB and CNTs during combustion. Rheological properties further confirmed that CB played an important role on promoting the formation of crosslink network on the base of PP/CNTs system, which were also responsible for the improved thermal stability and flame retardancy of PP. Copyright © 2013 John Wiley & Sons, Ltd.     

Melt‐extensional properties and orientation behaviors of polypropylene‐layered silicate nanocomposites

Polypropylene‐layered silicate nanocomposites consisting of three components—pure polypropylene, maleated polypropylene, and organically modified silicate—were prepared by the melt‐intercalation method to investigate melt‐extensional properties such as melt strength, neck‐in test, and orientation behavior. The nanocomposites showed an enhanced tensile modulus, enhanced storage modulus, much enhanced melt tension, and reduced neck‐in during the melt processing as compared with neat polymer. The uniaxial drawing induced the silicate surface to align parallel to the sheet surface. The c and a* axes of the polypropylene crystals were bimodally oriented to the flow direction, and the b axes were oriented to the thickness direction. The bimodal orientation of the polypropylene crystal was enhanced with the concentration of silicates. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 158–167, 2005     

Ultrahigh Molecular mass Polyethylene/ Carbon Nanotube CompositesCrystallization and melting properties

Ultrahigh molecular mass polyethylene (UHMMPE) is filled with carbon nano-tubes (CNTs) by solution in the presence of maleic anhydride grafted styrene-(ethylene-co-butylene)-styrene copolymer (MA-SEBS) as a compatibilizer. The UHMMPE/CNT composites crystallized from melt were prepared at a cooling rate of 20°C min^-1. The melting and crystallization behaviors of UHMMPE/ CNT composites were investigated by differential scanning calorimetry. The results showed that onset melting temperature (T _m) and degree of crystallinity (X _c) of UHMMPE/CNT composites crystallized from solution are higher than those from melt due to the larger crystalline lamellar thickness. The onset crystallization temperature (T _c) of UHMMPE/CNT composites tends to shift to higher temperature region with increasing CNT content in the composites. Tm and Tc of UHMMPE phase in UHMMPE/CNT composites decrease with the addition of MA-SEBS. Moreover, the crystallization rate of UHMMPE phase in UHMMPE/CNT composite is increased due to the introduction of CNTs. MA-SEBS acts as compatilizer, enhances the dispersion of CNTs in the UHMMPE matrix. Thereby, the crystallization rate of UHMMPE phase in UHMMPE/CNT composite is further increased with the addition of MA-SEBS. This revised version was published online in August 2006 with corrections to the Cover Date.     

Isothermal crystallization behavior of exfoliated‐PP/IMMT nanocomposites via in situ polymerization

Highly exfoliated isotactic‐polypropylene/alkyl‐imidazolium modified montmorillonite (PP/IMMT) nanocomposites have been prepared via in situ intercalative polymerization. TEM and XRD results indicated that the obtained composites were highly exfoliated PP/IMMT nanocomposites and the average thickness of IMMT in PP matrix was less than 10 nm, and the distance between adjacent IMMT particles was in the range of 20–200 nm. The isothermal crystallization kinetics of highly exfoliated PP/IMMT nanocomposites were investigated by using differential scanning calorimeter(DSC) and polarized optical microscope (POM). The crystallization half‐time t_1/2, crystallization peak time t_max, and the Avrami crystallization rate constant K_n showed that the nanosilicate layers accelerate the overall crystallization rate greatly due to the nucleation effect, and the crystallization rate was increased with the increase in MMT content. Meanwhile, the crystallinity of PP in nanocomposites decreased with the increase in clay content which indicated the PP chains were confined by the nanosilicate layers during the crystallization process. Although the well‐dispersed silicate layers did not have much influence on spherulites growth rate, the nucleation rate and the nuclei density increased significantly. Accordingly, the spherulite size decreased with the increase in MMT content. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 2215–2225, 2009     

Shear‐induced change of exfoliation and orientation in polypropylene/montmorillonite nanocomposites

For the improved dispersion of montmorillonite (MMT) in a polypropylene (PP) matrix, PP/MMT nanocomposites prepared via direct melt intercalation were further subjected to oscillating stress achieved by dynamic packing injection molding. The shear‐induced morphological changes were investigated with an Instron machine, wide‐angle X‐ray diffraction, scanning electron microscopy, and transmission electron microscopy. The original nanocomposites possessed a partly intercalated and partly exfoliated morphology. A transformation of the intercalated structure into an exfoliated structure occurred after shearing, and a more homogeneous dispersion of MMT in the PP matrix was obtained. However, the increase of the exfoliated structure was accompanied by the scarifying of the orientation of MMT layers along the shear direction. Some bended or curved MMT layers were found for the first time by TEM after shearing. However, the orientation of PP chains in the PP/MMT nanocomposites became very difficult under an external shear force; this indicated that the molecular motion of PP chains intercalated between MMT layers was highly confined. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 1–10, 2003     

Oligoaniline assisted dispersion of carbon nanotubes in epoxy matrix for achieving the nanocomposites with enhanced mechanical,thermal and tribological properties

A critical challenge for initiating many applications of the carbon nanotubes (CNTs) is their dispersion in organic solvent or in polymer melt. In the present study, we described a novel strategy for fabricating carbon nanotubes (CNTs)-reinforced epoxy nanocomposite by utilizing aniline trimer (AT) as the noncovalent dispersant. Tensile testing showed that the tensile modulus of the CNTs-reinforced epoxy composites was considerably improved by adding a small amount of AT functionalized CNTs. Additionally, the as-prepared CNTs-epoxy nanocomposites exhibited superior tribological properties with much lower frictional coefficients and wear rates compared to those of neat epoxy resin. The well dispersed AT-functionalized CNTs in epoxy matrix played an important role in enhancing the mechanical properties, as well as acting as a solid lubricant for improving the tribological performance of epoxy/CNTs nanocomposite.     

Formation of β‐iPP in isotactic polypropylene/ethylene–propylene rubber blends: Effects of preparation method,composition, and thermal condition

The effects of preparation method, composition, and thermal condition on formation of β‐iPP in isotactic polypropylene/ethylene–propylene rubber (iPP/EPR) blends were studied using modulated differential scanning calorimeter (MDSC), wide angle X‐ray diffraction (WAXD), and phase contrast microscopy (PCM). It was found that the α‐iPP and β‐iPP can simultaneity form in the melt‐blended samples, whereas only α‐iPP exists in the solution‐blended samples. The results show that the formation of β‐iPP in the melt‐blended samples is related to the crystallization temperature and the β‐iPP generally diminishes and finally vanishes when the crystallization temperature moves far from 125 °C. The phenomena that the lower critical temperature of β‐iPP in iPP/EPR obviously increases to 114 °C and the upper critical temperature decreases to 134 °C indicate the narrowing of temperature interval, facilitating the formation of β‐iPP in iPP/EPR. Furthermore, it was found that the amount of β‐iPP in melt‐blended iPP/EPR samples is dependent on the composition and the maximum amount of β‐iPP formed when the composition of iPP/EPR blends is 85:15 in weight. The results through examining the effect of annealing for iPP/EPR samples at melt state indicate that this annealing may eliminate the susceptibility to β‐crystallization of iPP. However, only α‐iPP can be observed in solution‐blended samples subjected to annealing for different time. The PCM images demonstrate that an obvious phase‐separation happens in both melt‐blended and solution‐blended iPP/EPR samples, implying that compared with the disperse degree of EPR in iPP, the preparation method plays a dominant role in formation of β‐iPP. It is suggested that the origin of formation of β‐iPP results from the thermomechanical history of the EPR component in iPP/EPR. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1704–1712, 2007     

Annealing induced electrical conductivity jump of multi‐walled carbon nanotube/polypropylene composites and influence of molecular weight of polypropylene

Multi‐walled carbon nanotube (MWCNT)/polypropylene (PP) composites were prepared by a micro melt mixing process. As‐prepared composites had relatively low electrical conductivity due to the disruption of MWCNT network by strong shear. The electrical conductivity jumped to high values throughout an annealing process above the melting temperature of PP. The significant enhancement of electrical conductivity was influenced by annealing time, temperature, and content of MWCNTs. In particular, molecular weight of PP played an important role in affecting the conductivity enhancement. The molecular weight of PP was varied from 190,000 to 340,000 to examine its effect on the electrical conductivity. By comparing the conductivity enhancement behavior of composites with different molecular weight PPs and observing the morphology evolution during annealing, it was found that reaggregation of MWCNTs and the subsequent formation of MWCNT network during annealing are the main reasons for the jump of electrical conductivity. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2010