New method for the synthesis of clay/epoxy nanocomposites

A new liquid–liquid method for the synthesis of epoxy nanocomposites was developed. This new method improved the dispersion and exfoliation of the organoclay in the polymer matrix, thus improving the end‐use properties. The microstructure and physical properties of the clay/epoxy nanocomposite synthesized by the new method were studied. Rheological tests of the uncured epoxy–organoclay system demonstrated that this method resulted in a great increase in viscosity, much more than the most commonly used direct‐mixing method. The Krieger–Dougherty model successfully described the dispersion of the clay layers in the uncured epoxy. In the 5 wt % organoclay nanocomposite, compressive tests on the cured samples showed that there was a 45% increase in the maximum strength, a 10% increase in the yield strength, and a 26% increase in the modulus over the pure epoxy–amine cured system. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 4286–4296, 2006     

Liquid‐crystalline epoxy thermosets as matrices for ordered nanocomposites—a summary of experimental studies

This work focuses on obtaining ordered liquid crystalline epoxy networks and applying them as matrices for nanofillers. The article summarizes research carried out by us on the synthesis and curing of a series of composites based on liquid crystalline epoxy monomers. The authors experimented with several factors which influence the crosslinking reaction and determined curing conditions which are the most favorable for developing liquid crystalline‐like molecular order in the final products. New results of curing selected mixtures with the addition of anisotropic fillers are also presented. The crosslinking process was followed by differential scanning calorimetry (DSC) measurements and the morphology of liquid crystalline epoxy resin (LCER) composites was investigated by wide‐angle X‐ray scattering technique (WAXS‐2D). The experiments demonstrated that nanorods only have a small impact on the thermal properties of the composite (e.g., the change of T _g is just about 2°C) as well as structural ones (diffraction images of the plain matrix and the nanocomposite only differ in a single additional reflection near 0.73 nm⁻¹ which appears in all the studied matrices containing nanorods). In one case monodomain ordering could be achieved in both the matrix alone and that with the nanofiller, when curing was conducted in the presence of a magnetic field. POLYM. COMPOS., 38:277–286, 2017. © 2015 Society of Plastics Engineers     

Preparation and characterization of microbial biodegradable poly(3‐hydroxybutyrate‐co‐4‐hydroxybutyrate)/organoclay nanocomposites

Novel biodegradable poly(3‐hydroxybutyrate‐co‐4‐hydroxybutyrate) [P(3HB‐co‐4HB)]/organoclay nanocomposites were prepared via solution casting. Exfoliated nanocomposite structure was confirmed by wide‐angle X‐ray diffraction (WAXD) and transmission electron microscopy (TEM) for the nanocomposites with low organoclay loadings (≤3 wt%), whereas the mixtures of exfoliated and unexfoliated organoclays were appeared in the nanocomposite with an organoclay content of 5 wt%. The organoclay fillers accelerated significantly the cold crystallization process of P(3HB‐co‐4HB) matrix. The thermal stability of the nanocomposites was in general better than that of pristine P(3HB‐co‐4HB). Considerable increase in tensile modulus was observed for the nanocomposites, especially at an organoclay content of 3 wt%. These results demonstrated that the nanocomposites improved the material properties of P(3HB‐co‐4HB). POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers     

Synthesis and properties of BCDA‐based polyimide–clay nanocomposites

Bicyclo[2.2.2]oct‐7‐ene‐2,3,5,6‐tetracarboxylic dianhydride (BCDA)‐based polyimide–clay nanocomposites were prepared from their precursor, namely polyamic acid, by a solution‐casting method. The organoclay was prepared by treating sodium montmorillonite (Kunipia F) clay with dodecyltrimethylammonium bromide at 80 °C. Polyamic acid solutions containing various weight percentages of organoclay were prepared from 4,4′‐(4,4′‐isopropylidenediphenyl‐1,1′‐diyldioxy)‐dianiline and BCDA in N‐methyl‐2‐pyrrolidone containing dispersed particles of organoclay at 20 °C. These solutions were cast on a glass plate using a Doctor's blade and then heated subsequently to obtain nanocomposite films. The nanocomposites were characterized using Fourier transform infrared spectroscopy, differential scanning calorimetry, thermal mechanical analysis, dynamic mechanical analysis, polarizing microscopy, scanning electron microscopy, transmission electron microscopy, wide‐angle X‐ray diffraction (WAXD) and thermogravimetric analysis. The glass transition temperature of the nanocomposites was found to be higher than that of pristine polymer. The coefficient of thermal expansion of the nanocomposites decreased with increasing organoclay content. WAXD studies indicated that the extent of silicate layer separation in the nanocomposite films depended upon the organoclay content. Tensile strength and modulus of the nanocomposite containing 1% organoclay were significantly higher when compared to pristine polymer and other nanocomposites. The thermal stability of the nanocomposites was found to be higher than that of pristine polymer in air and nitrogen atmosphere. Copyright © 2007 Society of Chemical Industry     

Effect of transfer film on tribological behavior of polyamide 66‐based binary and ternary nanocomposites

BACKGROUND: In a polymer–metal sliding system, the formation and performance of the transfer film have important effects on the tribological behavior of the polymer. In order to reveal the wear mechanism of polyamide 66 (PA 66) and its composites consisting of styrene–(ethylene/butylene)–styrene triblock rubber grafted with maleic anhydride (SEBS‐g‐MA) particles and organoclay nano‐layers, the tribological behavior and transfer films of polyamide 66 and its composites were investigated under dry sliding. RESULTS: The incorporation of SEBS‐g‐MA rubber particles reduces the wear mass loss of PA 66, while the addition of organoclay nano‐layers increases the wear mass loss. The transfer films formed by neat PA 66 and PA 66/organoclay binary nanocomposite include a dark portion and bright portion. In the dark portion, the transfer film is thicker; in the bright portion, the steel ring surface is exposed. The transfer film formed by PA 66/SEBS‐g‐MA/organoclay ternary nanocomposite is thinner and more uniform than the transfer films formed by the other materials. CONCLUSION: When SEBS‐g‐MA rubber particles and organoclay nano‐layers are added simultaneously to PA 66, the wear resistance of PA 66 can be improved markedly. The main reason is that PA 66/SEBS‐g‐MA/organoclay ternary nanocomposite can form a thin and uniform transfer film on the steel ring surface. Copyright © 2008 Society of Chemical Industry     

Synthesis and properties of polyimide (containing naphthalene) nanocomposites with organo‐modified montmorillonites

2,7‐Bis(4‐aminophenoxy) naphthalene (BAPN), a naphthalene‐containing diamine, was synthesized and polymerized with a 3,3′,4,4′‐benzophenone tetracarboxylic dianhydride (BTDA) to obtain a polyimide (PI) via thermal imidization. To enhance the thermal and mechanical properties of the polymer, PI–Montmorillonite (MMT) nanocomposites were prepared from a DMAc solution of poly(amic acid) and a DMAc dispersion of MMT, which were organo‐modified with various amounts of n‐dodecylamine (DOA) or cetylpyridium chloride (CPC). FTIR, XRD, and TEM (transmission electron microscopy) were used to verify the incorporation of the modifying agents into the clay structure and the intercalation of the organoclay into the PI matrix. Results demonstrated that the introduction of a small amount of MMT (up to 5%) led to the improvement in thermal stability and mechanical properties of PI. The decomposition temperature of 5% weight loss (T_d,5%) in N₂ was increased by 46 and 36°C in comparison with pristine PI for the organoclay content of 5% with DOA and CPC, respectively. The nanocomposites were simultaneously strengthened and toughened. The dielectric constant, CTE, and water absorption were decreased. However, at higher organoclay contents (5–10%), these properties were reduced because the organoclay was poorly dispersed and resulted in aggregate formation. The effects of different organo‐modifiers on the properties of PI–MMT nanocomposite were also studied; the results showed that DOA was comparable with CPC. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci, 2006     

Modification of an o‐cresol formaldehyde epoxy resin by the thermotropic liquid crystalline polymer

Two novel liquid crystalline polymers, polydiethyleneglycol bis(4‐hydroxybenzoate) terephthaloyl and block copolymer (PDBH), were synthesized by condensation reaction. The blends of the two liquid crystalline polymers and o‐cresol formaldehyde epoxy resin were prepared by linear phenol‐formaldehyde resin as curing reagent. Both mechanical and thermal properties of the blends containing liquid crystalline polymer were improved to a certain extent. By adding 5 wt % PDBH, the impact strength, bending strength, and the glass transition temperature were enhanced by 128%, 23.84%, and 28°C, respectively, compared with the unmodified version. The results of curing kinetics showed that the curing reaction active energy of the modified system by PDBH decreased from 79.70 to 70.26 kJ/mol. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 1626–1631, 2005     

Positive‐working aqueous base developable photosensitive polybenzoxazole precursor/organoclay nanocomposites

Positive‐working aqueous base developable photosensitive polybenzoxazole (PBO) precursor/organoclay nanocomposites have been prepared through the addition of an organoclay to a PBO precursor. The organoclay was formed by a cation exchange reaction between a Na⁺‐montmorillonite clay and an ammonium salt of dodecylamine. The PBO precursor used in this study was a polyhydroxyamide that was prepared from a low‐temperature polymerization of 2′2′‐bis(3‐amino‐4‐hydroxyphenyl) hexafluoropropane and 4,4′‐oxydibenzoyl chloride with an inherent viscosity of 0.3 dL/g. The photosensitive resin/clay formulations were prepared from the precursor with 2,3,4‐tris(1‐oxo‐2‐diazonaphthoquinone‐5‐sulfonyloxy)‐benzophenone photosensitive compound and 3–5 wt % organoclay. The PBO precursor/clay was subsequently thermally cured to PBO/clay at 350°C. Both X‐ray diffraction and transmission electron microscope analyses showed that the organoclay was dispersed in the PBO matrix in a nanometer scale. The thermal expansion coefficient of PBO/clay film, which contained 5 wt % organoclay, was decreased 33% compared to the pure PBO film. The PBO/clay nanocomposite films also displayed higher thermal stability, glass transition temperature, and water resistance than the pure PBO film. The photosensitive PBO precursor/clay nanocomposite showed a line/space pattern with a resolution of 5 μm and its sensitivity and contrast were not affected by the organoclay. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 2350–2356, 2005     

Preparation of poly(styrene‐co‐butyl acrylate)/montmorillonite nanocomposite by emulsion polymerization: Characterization and nanoscratch behavior

Organic–inorganic hybrid poly(styrene‐co‐butyl acrylate)/organically modified montmorillonite (PSBA/organo‐MMT) latex particles have been prepared by in situ emulsion polymerization. The effects of modifier variety and the level of organo‐MMT have been investigated on the basis of the characteristics and mechanical properties of the resulting hybrid emulsion polymers. Although the more hydrophilic intercalated organic modifiers increased the latex particle size, the hydrophobic ones decreased the particle size. A more heterogeneous copolymer chain intercalation was seen by widespread XRD reflection as the organo‐MMT (organoclay) level increases. The tapping mode atomic force microscopy (AFM) and transmission electron microscopy (TEM) were used to determine the dispersion state of organoclay particles inside the nanocomposite copolymer films. Dynamic mechanical thermal analysis (DMTA) showed that adding the organoclay to the copolymer decreased the maximum loss tangent (tanδ) value and caused the shift to a lower temperature. Interestingly, the incorporation of organoclay decreased the glass storage modulus of the copolymer, while increased the rubbery storage modulus to some extent. In addition, a standard indenter for the nanoscratching of copolymer nanocomposite films was used under low applied loads of 150 and 250 μN. The nanoscratch results showed that incorporation of a 3 wt % hydrophobic organoclay, e.g., Closite15A, in the copolymer matrix enhanced considerably the near‐surface hardness and grooving resistance of the nanocomposite film at room temperature. In fact, copolymer nanocomposite films with higher near‐surface hardness and tanδ curve broadening exhibited more nanoscratch resistance through a specific variety of viscoelastic deformation, which did not create a bigger groove. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Synthesis and characterization of thermotropic liquid crystalline poly(aryl ether ketone) copolymers with pendant 3‐(trifluoromethyl) phenyl groups

Novel poly(aryl ether ketone) copolymers with pendant 3‐(trifluoromethyl)phenyl groups were synthesized by the reaction of a crystal‐disrupting monomer, 3‐(trifluoromethyl)phenylhydroquinone (FH) and a mesogenic monomer, 4,4′‐biphenol (BP) with 1,4‐bis(p‐fluorobenzoyl)benzene (BF). Thermotropic liquid crystalline behavior of the copolymers was investigated by means of differential scanning calorimetry, polarized optical microscope and wide‐angle X‐ray diffraction. As a result, the copolymers with the respective molar ratios of FH/BP/BF of 0/100/100–10/90/100 and 80/20/100–100/0/100 were semi‐crystalline without liquid crystalline properties, and amorphous polymers, respectively. In contrast, copolymers with the molar ratio of FH/BP/BF of 20/80/100–70/30/100 had liquid crystalline characteristics. Interestingly, the formation of a highly ordered smectic phase was confirmed for copolymers with the molar ratio of FH/BP/BF of 20/80/100–50/50/100, respectively. All the liquid crystalline copolymers had a wide liquid crystalline temperature range (57–75 °C). Copyright © 2006 Society of Chemical Industry     

Effect of organic modifiers and silicate type on filler dispersion,thermal, and mechanical properties of ABS‐clay nanocomposites

Acrylonitrile–butadiene–styrene (ABS)–clay composite and intercalated nanocomposites were prepared by melt processing, using Na‐montmorillonite (MMT), several chemically different organically modified MMT (OMMT) and Na‐laponite clays. The polymer–clay hybrids were characterized by WAXD, TEM, DSC, TGA, tensile, and impact tests. Intercalated nanocomposites are formed with organoclays, a composite is obtained with unmodified MMT, and the nanocomposite based on synthetic laponite is almost exfoliated. An unintercalated nanocomposite is formed by one of the organically modified clays, with similar overall stack dispersion as compared to the intercalated nanocomposites. T_g of ABS is unaffected by incorporation of the silicate filler in its matrix upto 4 wt % loading for different aspect ratios and organic modifications. A significant improvement in the onset of thermal decomposition (40–44°C at 4 wt % organoclay) is seen. The Young's modulus shows improvement, the elongation‐at‐break shows reduction, and the tensile strength shows improvement. Notched and unnotched impact strength of the intercalated MMT nanocomposites is lower as compared to that of ABS matrix. However, laponite and overexchanged organomontmorillonite clay lead to improvement in ductility. For the MMT clays, the Young's modulus (E) correlates with the intercalation change in organoclay interlayer separation (Δd₀₀₁) as influenced by the chemistry of the modifier. Although ABS‐laponite composites are exfoliated, the intercalated OMMT‐based nanocomposites show greater improvement in modulus. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Flame retardancy and mechanical properties of polyamide 6 with melamine polyphosphate and ionic liquid surfactant‐treated montmorillonite

The mechanical properties and inflammability of polyamide 6 (PA6) nanocomposites incorporated with Montmorillonite organoclay (MMT) modified with thermal stable ionic liquid surfactants were investigated. The compatibility between ionic liquid‐treated MMT and PA6 matrix was improved and the intercalation morphology was achieved, which resulted in the increaseof tensile modulus. However, the addition of organo‐MMTs alone did not improve the inflammability of the PA6 nanocomposite, because of strong melt‐dripping behavior of PA6 matrix. Addition of auxiliary melamine polyphosphate (MPP) intumescent flame retardant to the nanocomposite prevented the melt dripping and enhanced inflammability performance. The enhanced inflammability of PA6/organoclay/MPP nanocomposites was attributed to the synergistic effect between imidazolium or phosphonium organo‐MMTs and intumescent flame retardant MPP. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40648.     

Thermomechanical and electrical characterization of epoxy‐organoclay nanocomposites

The effect of amount of clay content on the thermomechanical and electrical properties of epoxy/organoclay nanocomposites is investigated in the present research. An organoclay, cloisite 30B (C30B), was dispersed in the epoxy resin and was cured with an amine curing agent. The morphology of the nanocomposite examined by X‐ray diffraction shows exfoliation for nanocomposites with lesser clay content and intercalation for nanocomposites with higher clay content. The storage modulus (E′) of the nanocomposites increases monotonously with the increase in the amount of clay. The short time alternating current breakdown strength of the nanocomposites increases by the addition of C30B up to a certain clay content and then show a decrease. The space charge measured by pulsed electroacoustic method shows that the nanocomposite accumulate a very less amount of space charge and the charge decay in the nanocomposites are quicker than in the pure polymer. POLYM. ENG. SCI., 2012. © 2011 Society of Plastics Engineers     

Morphology and thermal/mechanical properties of alkyl‐imidazolium‐treated rectorite/epoxy nanocomposites

A novel organic rectorite (OREC) was prepared by treating the natural sodium‐rectorite (Na‐REC) with ionic liquid 1‐hexadecyl‐3‐methylimidazolium bromide ([C₁₆mim]Br). X‐ray diffraction (XRD) analysis showed that the interlayer spacing of the OREC was expanded from 2.23nm to 3.14nm. Furthermore, two types of OREC/epoxy nanocomposites were prepared by using epoxy resin (EP) as matrix, 2‐ethyl‐4‐methylimidazole (2‐E‐4‐MI) and tung oil anhydride (TOA) as curing agents, respectively. XRD and transmission electron microscope (TEM) analysis showed that the intercalated nanocomposite was obtained with addition of the curing agent 2‐E‐4‐MI, and the exfoliated nanocomposite was obtained with addition of the curing agent TOA when the OREC content was less than 2 wt %. For the exfoliated nanocomposite, the mechanical and thermal property tests indicated that it had the highest improvement when OREC content was 2 wt% in EP. Compared to pure EP, 60.3% improvement in tensile strength, 26.7% improvement in bending strength, 34% improvement in bending modulus, 14°C improvement in thermal decomposition temperature (T_d) and 5.7°C improvement in glass transition temperature (T_g) were achieved. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Study on dispersion and intercalation of organoclay in PP and PP‐g‐MA matrices

Understanding the complex mechanism of dispersion and intercalation of the clay tactoids can allow us to control the final morphology, homogeneity, and the macroscopic properties of clay nanocomposites. The objective of this work is a multiscale study of the dispersion state of PP/organoclay and PP‐g‐MA/organoclay composite. The microscopic investigation, WAXS diffractograms, rheological analysis, and mechanical properties were used to characterize the dispersion of organoclay in PP and PP‐g‐MA matrices during melt blending in two different shear rates. The morphological results show a system of aggregating intercalated clay particles which disperse by increasing mixing time with a strain‐controlled process and a very quick intercalation process in early mixing times for PP‐g‐MA/organoclay nanocomposite, while PP/organoclay samples only form microcomposites. The relative network modulus of these intercalated particles as a function of mixing time was obtained; and the tensile modulus of nanocomposite samples were compared with Halpin‐Tsai model prediction. POLYM. COMPOS., 2009. © 2009 Society of Plastics Engineers     

Effects of nanoclay on the properties of cardanol‐modified‐resol‐epoxy‐novolac composite material

A nanocomposite based on nanoclay and resol that was modified with cardanol, a natural alkyl phenol, shows improvement for the glass‐fiber‐reinforced epoxy‐composite system. Dispersion of the nanocomposite was investigated by X‐ray, showing good results obtained by the in situ polymerization method. The mechanical properties of the final composites were improved by doping a 6 wt% of nanoclay in cardanol‐modified‐resol (CMR) into the epoxy matrix. The results show that a 15 wt% of CMR in epoxy is a most suitable ratio. Using polyamide as a curing agent instead of other traditional systems, such as anhydrides or amines for epoxy resin, overcame important limitations, further allowing for improved processability. The overall composite performance was enhanced. Additionally, the thermal stability of the system was investigated by thermal gravimetric analysis. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 3238–3242, 2007     

Graft copolymerization of thiophene onto polystyrene synthesized via nitroxide‐mediated polymerization and its polymer − clay nanocomposite

A new strategy for graft copolymerization of thiophene onto a polystyrene (PSt) backbone by a multi‐step process is suggested and the effects of an organoclay on the final properties of the graft copolymer sample are described. For this purpose, first poly(styrene‐co‐4‐chloromethyl styrene) [P(St‐co‐CMSt)] was synthesized via nitroxide‐mediated polymerization. Afterwards, the chlorine groups of P(St‐co‐CMSt) were converted to thiophene groups using the Kumada cross‐coupling reaction and thiophene‐functionalized PSt multicenter macromonomer (ThPStM) was synthesized. The graft copolymerization of thiophene monomers onto PSt was initiated by oxidized thiophene groups in the PSt chains after addition of ferric chloride (FeCl₃), an oxidative catalyst for polythiophene synthesis, and FeCl₃‐doped polythiophene was chemically grafted onto PSt chains via oxidation polymerization. The graft copolymer obtained was characterized by ¹H NMR and Fourier transform infrared spectroscopy, and its electroactivity behavior was verified under cyclic voltammetric conditions. Finally, PSt‐g‐PTh/montmorillonite nanocomposite was prepared by a solution intercalation method. The level of dispersion of organoclay and the microstructure of the resulting nanocomposite were probed by means of XRD and transmission electron microscopy. It was found that the addition of only a small amount of organoclay (5 wt%) was enough to improve the thermal stabilities of the nanocomposite.© 2013 Society of Chemical Industry     

SiAlON–epoxy nanocomposite coatings: Corrosion and wear behavior

In this study, epoxy powder as a matrix was combined with different contents of silicon–aluminum–oxygen–nitrogen (SiAlON) nanoparticles using a planetary ball mill. Pure epoxy and nanocomposite powders were applied on the surface of plain carbon steel components by the electrostatic spraying method. Curing of the coatings was done in an oven or microwave for the appropriate time. The coating structure and morphology of the SiAlON nanoparticles were studied by scanning electron microscopy and transmission electron microscopy, respectively. The corrosion properties of the coatings were assessed by immersion, Tafel polarization, and electrochemical impedance spectroscopy tests in 3.5% NaCl solution. The results show that addition of 10 wt % SiAlON nanoparticles markedly increases the corrosion resistance of epoxy coatings. Thus, it can be inferred that the corrosion rate of these coatings is 15 to 18 times lower than that of pure epoxy samples and 8 to 11 times lower than coatings with 20 wt % SiAlON. The higher corrosion resistance of nanocomposite coatings can be attributed to the barrier properties of SiAlON nanoparticles. The tribological performance of the coatings was studied with the pin‐on‐disk test. The results of wear testing show that the samples containing 10 wt % SiAlON provide about five times more wear resistance than pure ones and about two times more than coatings with 20 wt % SiAlON. However, the coefficient of friction for nanocomposite coatings is reduced about 50% compared to the pure sample. Also, the curing process in either regime (oven or microwave) has the same effect on the corrosion and wear properties, and the coatings are completely crosslinked. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43855.     

Organoclay/thermotropic liquid crystalline polymer nanocomposites. Part VI: Effects of intercalated organoclay on nanocomposite morphology,thermal and rheological properties

A study of a typical intercalated structure of a thermotropic liquid crystalline polymer (TLCP) with organoclay was performed to elucidate the influence of intercalated organoclay on the TLCP molecules, especially on their liquid crystallinity, thermal and rheological properties. The intercalated structures were confirmed in TLCP and organoclay formed molecular interactions with TLCP molecules in the system. Such intercalated structures caused the glass transition temperature of the nanocomposite to become invisible in thermal measurement and also caused loss of liquid crystallinity. The TLCP molecules inside the organoclay galleries showed higher thermal stability and transition temperatures, but the orderly structure of the TLCP molecules outside the galleries was destroyed by the organoclay, causing the TLCP to display lower thermal stability and transition temperatures than pristine TLCP. At 185°C, where TLCP is in the nematic phase, the nanocomposite had three orders of magnitude higher viscosity in the linear viscoelastic region than that of TLCP, with chain mobility and relaxation time slowed due to the intercalated effects in the nanocomposite. Steady shear altered the domain sizes and oriented the highly anisotropic organoclay layers or tactoids along the shear direction.     

Biodegradable and functionally superior starch–polyester nanocomposites from reactive extrusion

Biodegradable starch‐polyester polymer composites are useful in many applications ranging from numerous packaging end‐uses to tissue engineering. However the amount of starch that can form composites with polyesters without significant property deterioration is typically less than 25% because of thermodynamic immiscibility between the two polymers. We have developed a reactive extrusion process in which high amounts of starch (approx. 40 wt%) can be blended with a biodegradable polyester (polycaprolactone, PCL) resulting in tough nanocomposite blends with elongational properties approaching that of 100% PCL. We hypothesize that starch was oxidized and then crosslinked with PCL in the presence of an oxidizing/crosslinking agent and modified montmorillonite (MMT) organoclay, thus compatibilizing the two polymers. Starch, PCL, plasticizer, MMT organoclay, oxidizing/crosslinking agent and catalysts were extruded in a co‐rotating twin‐screw extruder and injection molded at 120° C. Elongational properties of reactively extruded starch‐PCL nanocomposite blends approached that of 100% PCL at 3 and 6 wt% organoclay. Strength and modulus remained the same as starch‐PCL composites prepared from simple physical mixing without any crosslinking. X‐ray diffraction results showed mainly intercalated flocculated behavior of clay at 1,3,6, and 9wt% organoclay. Scanning electron microscopy (SEM) showed that there was improved starch‐PCL interfacial adhesion in reactively extruded blends with crosslinking than in starch‐PCL composites without crosslinking. Dynamic mechanical analysis showed changes in primary α‐transition temperatures for both the starch and PCL fractions, reflecting crosslinking changes in the nanocomposite blends at different organoclay contents. Also starch‐polytetramethylene adipate‐co‐terephthalate (PAT) blends prepared by the above reactive extrusion process showed the same trend of elongational properties approaching that of 100% PAT. The reactive extrusion concept can be extended to other starch‐PCL like polymer blends with polymers like polyvinyl alcohol on one side and polybutylene succinate, polyhydroxy butyrate‐valerate and polylactic acid on the other to create cheap, novel and compatible biodegradable polymer blends with increased toughness. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 96: 1072–1082, 2005