Structure–property relationships of polymer blend/clay nanocomposites: Compatibilized and noncompatibilized polystyrene/propylene/clay

Polymer blends represent an important class of materials in engineering applications. The incorporation of clay nanofiller may provide new opportunities for this type of materials to enhance their applications. This article reports on the effects of clay on the structure and properties of compatibilized and noncompatibilized polymer blends and presents a detailed process for quantitative analysis of the elastic moduli of polymer blend/clay nanocomposites, based on immiscible polystyrene/polypropylene (PS/PP) blends with or without maleated PP as the compatibilizer. The results show that in the noncompatibilized PS/PP/clay nanocomposite clay locates solely in the PS phase, whereas in the compatibilized nanocomposite clay disperses in both phases. The addition of clay to both polymer blends reduces the domain size significantly, modifies the crystallinity and improves the stiffness. The Mori–Tanaka and Christensen's models offer a reasonably good prediction of the elastic moduli of both types of nanocomposites. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2012     

Morphology evolution and location of ethylene–propylene copolymer in annealed polyethylene/polypropylene blends

Binary blends of linear low density polyethylene (PE) and polypropylene (PP), and ternary blends of PE, PP, and EP copolymer (EPR) were prepared in a finely mixed state. In all blends the ratio of PP to PE was 85/15. In some of the blends, the PE component was labeled with a fluorescent dye; in other blends, the EPR component was labeled. These blends were investigated by laser scanning confocal fluorescence microscopy [LCFM] as a function of annealing time as well as EPR compatibilizer content. In this way we were able to follow the evolution of sample morphology and the location of the EPR in the blends. The presence of EPR in the blends retards the growth of droplets of the dispersed PE phase. When EPR was added in amounts up to 5 wt %, it tended to cover the PE droplets in patches rather than form a true core-shell structure. In the LCFM images, the EPR/PP interface appeared sharper than the EPR/PE interface. © 1997 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 35 : 979–991, 1997     

Combined effects of clay modifications and compatibilizers on the formation and physical properties of melt‐mixed polypropylene/clay nanocomposites

The melt mixing technique was used to prepare various polypropylene (PP)‐based (nano)composites. Two commercial organoclays (denoted 20A and 30B) served as the fillers for the PP matrix, and two different maleated (so‐called) compatibilizers (denoted PP‐MA and SMA) were employed as the third component. The results from X‐ray diffraction (XRD) and transmission electron microscope (TEM) experiments revealed that 190 °C was an adequate temperature for preparing the nanocomposites. Nanocomposites were achieved only if specific pairs of organoclay and compatibilizer were simultaneously incorporated in the PP matrix. For example, PP/20A(5 wt %)/PP‐MA(10 wt %) and PP/30B(5 wt %)/SMA(5 wt %) composites exhibited nanoscaled dispersion of 20A or 30B in the PP matrix. Differential scanning calorimetry (DSC) results indicated that the organoclays served as nucleation agents for the PP matrix. Generally, their nucleation effectiveness increased with the addition of compatibilizers. The thermal stability enhancement of PP after adding 20A was confirmed with thermogravimetric analysis (TGA). The enhancement became more evident as a suitable compatibilizer was further added. However, for the 30B‐included composites, thermal stability enhancement was not evident. The dynamic mechanical properties (i.e., storage modulus and loss modulus) of PP increased as the nanocomposites were formed; the properties increment corresponded to the organoclay dispersion status in the matrix. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 4139–4150, 2004     

Preparation and properties of isobutylene–isoprene rubber–clay nanocomposites

Isobutylene isoprene rubber (IIR)‐clay nanocomposites have been prepared successfully by melt intercalation with maleic anhydride‐grafted IIR (Ma‐g‐IIR) and organophilic clay. In IIR‐clay nanocomposites, the silicate layers of the clay were exfoliated and dispersed into the monolayer. The nanocomposites exhibited greater gas barrier properties compared with those of Ma‐g‐IIR. When 15 phr clay was added, gas barrier properties were 2.5 times greater than those of Ma‐g‐IIR. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1182–1188, 2006     

Mechanical properties of polymer‐blend nanocomposites with organoclays: Polystyrene/ABS and high impact polystyrene/ABS

Thirty‐three polystyrene (PS)/acrylonitrile‐butadiene‐styrene (ABS) and high impact PS/ABS polymer blends with organoclay and copolymer additives were prepared by melt processing using different mixing sequences in order to test the putative capability of clay to perform a compatibilizing role in polymer blends. In general, the addition of clay increased the tensile modulus and had little effect on tensile strength. For the blends studied in this work, the addition of organoclays caused a catastrophic reduction in impact strength, a critical property for commercial viability. The polymer‐blend nanocomposites adopted a structure similar to that for ABS/clay nanocomposites as determined by X‐ray diffraction and transmission electron microscopy. It is suggested that clay reinforcement inhibits energy absorption by craze formation and shear yielding at high strain rates. Simultaneous mixing of the three components provided nanocomposites with superior elongation and energy to failure compared to sequential mixing. The clay pre‐treated with a benzyl‐containing surfactant gave the best overall properties among the various organoclays tested and of the two clay contents studied 4 wt % was preferred over 8 wt % addition. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2011     

Structure and mechanical properties for binary blends of polypropylene and ethylene‐1‐hexene copolymer

The structure and mechanical properties of the injection‐molded products for the binary blends composed of an isotactic polypropylene (PP) and a rubbery ethylene‐1‐hexene copolymer (EHR) were studied. The following two types of blends were employed: one is the incompatible blend of PP and ethylene‐rich EHR; the other is the compatible blend of PP and 1‐hexene‐rich EHR. The incompatible blend shows a phase‐separated morphology, in which EHR domains in the skin layer highly orient to the flow direction. On the other hand, the compatible blend shows fairly homogeneous morphology in the skin and core regions, in which EHR molecules are dissolved into the amorphous PP region. The measurements of birefringence and infrared dichroism revealed that the magnitude of molecular orientation along the flow direction for the compatible blend is larger than that for the incompatible blend. Nevertheless, it was also found that anisotropy of the mechanical properties for the compatible blend is less prominent, which is attributed to lack of the mechanical connection between neighbor crystalline fragments aligned perpendicular to the flow direction. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 701–713, 1999     

Influence of the compatibilizer polarity and molar mass on the morphology and the gas barrier properties of polyethylene/clay nanocomposites

In this study, different modified polyethylenes with different molar masses and different modification rates were examined as compatibilizers to prepare high density polyethylene/organoclay nanocomposites. Nanocomposites having 5 wt % organo-modified clay and 20 wt % interfacial agent were prepared by melt blending. The effect of compatibilizer molar mass and polarity was investigated on the clay dispersion and on the gas barrier properties. It was observed that the amount of large and dense fillers aggregates was considerably reduced by introduction of an interfacial agent. The nanocomposite final morphology was governed by a diffusion/shear mechanism. A high degree of clay delamination was obtained with the high molar mass compatibilizers, whereas highly swollen clay aggregates resulted from the incorporation of the low molar mass interfacial agents. In the investigated nanocomposites series, the barrier properties could not be directly related to the clay dispersion state but resulted also from the matrix/clay interfacial interactions. A gas transport mechanism based on these both parameters was proposed to explain the barrier properties evolution in these low polar nanocomposites series. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 2593–2604, 2008     

Effect of silane‐grafted polypropylene on the morphology of polypropylene and nylon 6/clay composites

Polypropylene (PP)/nylon 6/clay composites were prepared by compounding of PP, which had previously been treated with two kinds of silane compounds, with a master batch composed of 90 wt % of nylon 6 and 10 wt % of octadecyl amine‐modified sodium montmorillonite (NM10). The morphology of the composites was investigated by means of SEM, TEM, XRD, and energy‐dispersive X‐ray analysis. All of the composites exhibited a phase‐separated morphology, irrespective of whether the PP was modified with the silane compounds or not. However, adhesive strength between the modified PP and NM10 was stronger than that between neat PP and NM10. Moreover, the PP grafted with 3‐(trimethoxysilyl)propyl methacrylate (PP2) reacted with the silanol groups of the clay to form PP‐clay hybrid during the compounding, which acted as a compatibilizer for the PP/nylon 6/clay composite. PP2NM composite (PP2/NM10 80/20 on weight basis) exhibited a peculiar morphology, in that the PP‐rich phase formed island domains within the nylon 6‐rich domains, which were in turn dispersed in the PP‐rich continuous matrix. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 607–615, 2007.     

Melt blending of ethylene‐vinyl alcohol copolymer/clay nanocomposites: Effect of the clay type and processing conditions

Ethylene‐vinyl alcohol copolymer (EVOH)/clay nanocomposites were prepared via dynamic melt blending. The effect of the processing parameters on blends containing two clay types in different amounts was examined. The blends were characterized with a Brabender plastograph and capillary rheometer, differential scanning calorimetry, dynamic mechanical thermal analysis (DMTA), X‐ray diffraction (XRD), transmission electron microscopy (TEM), and thermogravimetric analysis (TGA). XRD showed advanced EVOH intercalation within the galleries, whereas TEM images indicated exfoliation, thereby complementing the XRD data. A dilution process with EVOH and clay treatment in an ultrasonic bath before melt blending did not add to the intercalation level. Different trends were observed for the EVOHs containing two different clay treatments, one claimed to be treated for EVOH and the other for amine‐cured epoxy. They reflected the differences in the amounts of the strongly interacting polymer for the two nanocomposites. Thermal analysis showed that the melting temperature, crystallization temperature, and heat of fusion of the EVOH matrix sharply decreased with both increasing clay content and processing times. Significantly higher viscosity levels were obtained for the blends in comparison with those of the neat polymer. The DMTA spectra showed higher glass‐transition temperatures for the nanocomposites in comparison with those of the neat EVOH. However, at high clay loadings, the glass‐transition temperature remained constant, presumably because of an adverse plasticizing effect of the low moleculared mass onium ions treating the clays. The storage modulus improved when clay treated for EVOH was used, and it deteriorated when amine‐cured epoxy clay was incorporated, except for the sonicated clay. TGA results showed significant improvements in the blends' thermal stability in comparison with that of the neat EVOH, which, according to TEM, was greater for the intercalated structures rather than for exfoliated ones. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 1741–1753, 2002     

Evaluation of ammonium terminated PMMA as compatibilizers for monomer casting polyamide6/clay nanocomposites

The compatibilization effects provided by ammonium terminated PMMA(PMMA‐t‐NH₃⁺) on monomer casting polyamide6 (MCPA6)/clay(pristine sodium montmorillonite) nanocomposites were studied in this article. PMMA‐t‐NH₃⁺ used in this study was prepared by radical polymerization using 2‐aminoethanethiol hydrochloride as chain transfer agent. MCPA6/clay/PMMA‐t‐NH₃⁺ nanocomposites were prepared by in situ anionic ring‐opening polymerization of ε‐caprolactam. X‐ray diffraction and transmission electron microscopy plus rheological measurement were used to characterize those nanocomposites. The results indicated that PMMA‐t‐NH₃⁺ would be a good compatibilizer for this system. With PMMA‐t‐NH₃⁺ content increasing, a better dispersion of clay was successfully achieved in the MCPA6 matrix. Furthermore, analysis using differential scanning calorimetry indicated that well dispersed clay layers limited the mobility of the MCPA6 molecule chains to crystallize, reduce the crystalline degree, and favor the formation of the γ‐crystalline form of the MCPA6 matrix. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 1802–1810, 2008     

Effect of nucleating agent on the brittle–ductile transition behavior of polypropylene/ethylene–octene copolymer blends

In the present work, α‐form nucleating agent 1,3:2,4‐bis (3,4‐dimethylbenzylidene) sorbitol (DMDBS, Millad 3988) is introduced into the blends of polypropylene/ethylene–octene copolymer (PP/POE) blends to study the effect of the nucleating agent on the toughness of PP/POE blends through affecting the crystallization behavior of PP matrix. Compared with the PP/POE blends, in which the toughness of the blends increases gradually with the increasing content of POE and only a weak transition in toughness is observed, addition of 0.2 wt % DMDBS induces not only the definitely brittle‐ductile transition at low POE content but also the enhancement of toughness and tensile strength of the blends simultaneously. Study on the morphologies of impact‐fractured surfaces suggests that the addition of a few amounts of DMDBS increases the degree of plastic deformation of sample during the fracture process. WAXD results suggest that POE induces the formation of the β‐form crystalline of PP; however, DMDBS prevents the formation of it. SEM results show that the addition of DMDBS does not affect the dispersion and phase morphologies of POE particles in PP matrix. DSC and POM results show that, although POE acts as a nucleating agent for PP crystallization and which enhances the crystallization temperature of PP and decreases the spherulites size of PP slightly, DMDBS induces the enhancement of the crystallization temperature of PP and the decrease of spherulites size of PP more greatly. It is concluded that the definitely brittle–ductile transition behavior during the impact process and the great improvement of toughness of the blends are attributed to the sharp decrease of PP spherulites size and their homogeneous distribution obtained by the addition of nucleating agent. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 577–588, 2008     

Effects of clay on polymorphism of polypropylene in polypropylene/clay nanocomposites

The effects of clay on polymorphism of polypropylene (PP) in PP/clay nanocomposites (PPCNs) under various thermomechanical conditions were studied. In extruded PP and PPCN pellet samples, only α-phase crystallites existed, as they were prepared by rapidly cooling the melt extrudates to room temperature. Under compression, β-phase crystallites can develop in neat PP under various thermal conditions, of which isothermal crystallizing at 120 °C gave the highest content of β-phase crystallites. In contrast, no β-phase crystallite was detected in the PPCN samples prepared under the same conditions. This indicated that clay significantly inhibits the formation of β-phase crystallites. The likely reason is that the presence of clay in PPCNs greatly sped up the crystallization process of the α phase, whereas it had an insignificant effect on the crystallization rates of the β phase. The results also showed that clay may slightly promote the formation of γ-phase PP crystallites in PPCNs. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 1810–1816, 2004     

An experimental and theoretical mechanistic analysis of thermal degradation of polypropylene/polylactic acid/clay nanocomposites

Polypropylene/polylactic acid (PP/PLA) blends containing 5 wt% of nanoclay in presence and absence of an ethylene‐butylacrylate‐glycidyl methacrylate terpolymer as compatibilizer were prepared by melt‐mixing process. A matrix‐droplet–type morphology confirmed by transmission electron microscope (TEM) and scanning electron microscopy (SEM) studies is formed in presence and absence of the compatibilizer in which the clay platelets were mainly localized in the polylactic acid (PLA) dispersed phase. Degradation studies by means of thermogravimetry analysis (TGA) and analysis of degradation activation energy (E_a), T_max (maximum degradation temperature), and ΔT (difference between initial and final degradation temperatures) parameters for each polymer component of the system revealed that incorporation of less stable PLA phase to polypropylene (PP) decreases E_a and T_max parameters, and hence, reduces the thermal stability of PP phase, while incorporation of clay nanoplatelets to the neat blend further reduces its thermal stability attributed to their lack of localization in PP phase. Compatibilization of the filled system results in migration of clay nanoplatelets toward PP and improves E_a and T_max of PP phase. On the other hand, the E_a and T_max of PLA phase of the blend were increased with incorporation of clay and its localization within that phase, while compatibilization of the filled system slightly reduces thermal stability of PLA phase due to migration of clay toward PP. A correlation was found between E_a and intensity of the thermogravimetry analysis Fourier‐transform infrared spectroscopy (TGA‐FTIR) peaks of the evolved products. Using the Criado method, a detailed analysis on degradation mechanism of each component was performed, and the changes in the degradation mechanism of the developed systems were determined.     

Barrier property of clay/Acrylonitrile‐butadiene copolymer nanocomposite

The resistance to air permeation was investigated for ­an intercalated clay/acrylonitrile‐butadiene copolymer ­nanocomposite. The nanocomposite is prepared by melt mixing the organo‐treated montmorillonite into a rubber matrix, together with peroxide curative, and crosslinked by conventional compression molding for typical rubbers. In the case of intercalated nanocomposite, the air permeability decreases considerably with increasing clay content, and the decreasing trend agrees reasonably with the Neilson's tortuous model. No considerable improvement is found when the pure montmorillonite is added. Copyright © 2002 John Wiley & Sons, Ltd.     

Intercalated clay nanocomposites: Morphology,mechanics, and fracture behavior

Intercalated nanocomposites of modified montmorillonite clays in a glassy epoxy were prepared by crosslinking with commercially available aliphatic diamine curing agents. These materials are shown to have improved Young's modulus but corresponding reductions in ultimate strength and strain to failure. The results were consistent with most particulate‐filled systems. The macroscopic compressive behavior was unchanged, although the failure mechanisms in compression varied from the unmodified samples. The fracture toughness of these materials was investigated and improvements in toughness values of 100% over unmodified resin were demonstrated. The fracture‐surface topology was examined using scanning electron and tapping‐mode atomic force microscopies and shown to be related to the clay morphology of the system. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 1137–1146, 2001     

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.     

High diffusion barrier and piezoelectric nanocomposites based on polyvinylidene fluoride‐trifluoroethylene copolymer and hydrophobized clay

Nanocomposites based on polyvinylidene fluoride–trifluoroethylene copolymer and up to 4 vol % of hydrophobized clay nanoparticles are investigated. The structure, piezoelectric properties, and oxygen permeability of solvent cast films are analyzed before and after annealing above the Curie temperature of the polymer. Exfoliation of the clay takes place at concentrations up to 1 vol %, beyond which it rapidly drops and is absent at a concentration of 4 vol %. The presence of clay does not change the crystallinity of the polymer, but leads to a threefold decrease of the oxygen permeability at a concentration of 0.5 vol %. Annealing at 130 °C increases the crystallinity, the proportion of β phase up to 94%, and the piezoelectric coefficient by 20–40% at clay fractions below 1 vol %. Annealing also leads to a remarkable 3‐ to 10‐fold decrease of O₂ permeability and to intriguing changes of the activation energy for O₂ transport, which decreases from 56 kJ/mol for the as‐cast polymer to below 10 kJ/mol for the polymer and exfoliated composite. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 1828–1836     

Facile synthesis and applications of polypropylene/polydimethylsiloxane graft copolymer

It is of great significance to synthesize polyolefin/polysiloxane hybrid materials due to their unique combination of crystalline polyolefin segments and semiorganic polysiloxane segments. Herein, we report the syntheses of a novel polypropylene/polydimethylsiloxane (PP‐g‐PDMS) graft copolymer via the coupling reactions between maleic anhydride‐grafted PP and monoaminopropyl‐terminated PDMS. The chemical structures of PP‐g‐PDMS have been characterized by Fourier transform infrared (FTIR), nuclear magnetic resonance (NMR), and gel permeation chromatography (GPC). The correlation between reaction conditions and the structural parameters of PP‐g‐PDMS has been established. Consequently, the potential applications of resultant PP‐g‐PDMS were investigated, and the results showed that PP‐g‐PDMS can serve as an efficient compatibilizer in heterogeneous PP/PDMS blend system and also as an ideal processing aid for high‐viscosity PP.     

Carboxylate clays: A model study for polypropylene/clay nanocomposites

Sodium-montmorillonite was intercalated by carboxylate salts to prepare carboxylate clays. The intercalation of sodium acetate doubles the clay basal spacing and no degradation of the carboxylate clay is noticed in the extrusion temperature range. These carboxylate clays were used to synthesize polypropylene-graft-maleic anhydride (PP-g-MA)/clay nanocomposites. Nanocomposites were also produced by a one-pot process using in situ prepared carboxylate clay. The carboxylate salts within the clay layers partially neutralize the maleic anhydride groups of the PP-g-MA matrix, in situ during the melt compounding. The ionic groups of the partially neutralized polymer offer favourable interactions with the clay, hence reinforcing the interfacial bond between the polymer and the clay and improving the composite properties. The use of carboxylate clay clearly improves the clay dispersion into the PP-g-MA matrix and improves the nanocomposite’s thermal and rheological properties.     

Effect of novel compatibilizers on the properties and morphology of PP/PC blends

A series of compatibilizers, including polypropylene (PP) grafted with 2‐tertbutyl‐6‐(3‐tertbutyl‐ 2‐hydroxy‐5‐methylbenzyl)‐4‐methylphenyl acrylic ester (BPA), glycidyl methacrylate (GMA), GMA/styrene (GMA‐st), and 2‐allyl bisphenol A (2A) were investigated for the purpose of improving the compatibility of PP/polycarbonate (PC) blends. PP‐g‐BPA shows a remarkable compatibilizing effect on PP/PC blends since it has similar group‐benzene ring with PC, and it is a sort of heat‐resistant antioxidant in the meantime, which can reduce the molecular degradation of PP during grafting and blending under high temperatures. Its compatibilizing effect was examined in terms of the mechanical, thermal properties, and morphologies. PP/PC blends show a decreasing and much more homogeneous size of dispersed PC particles through addition of a small amount of PP‐g‐BPA, and dynamic mechanical analysis (DMA) reveals a noticeable approach of T_g between PP and PC, indicating the improvement of the compatibility of PP/PC blends. Furthermore, styrene‐ethylene‐butylene‐styrene (SEBS) as a toughening rubber and a compatibilizer was applied to PP/PC blends. Around 25 wt% SEBS and 20 wt% PC lead to high toughness and strength of PP. Copyright © 2008 John Wiley & Sons, Ltd.