Structure and properties of phenolic resin/nanoclay composites synthesized by in situ polymerization

An in situ semibatch polymerization process for making phenolic resin/montmorillonite clay nanocomposites is developed. It is found that auxiliary mixing in phenol allows intercalation of the monomer and polymer between montmorillonite clay layers. At 2.7% clay by mass the montmorillonite is predominantly exfoliated (fully dispersed). At higher clay loading, a substantial amount of the clay remains in aggregate or intercalated form. When the montmorillonite is exfoliated, the material is mechanically superior. The composite has a tensile modulus that is 21% higher than the neat resin and has 87% improved fracture strength, 100% larger fracture energy, and strain to failure 13% above the pure resin. Thermogravimetric analysis shows the montmorillonite system maintains its thermal stability up to 200°C. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 1169–1174, 2005     

The effect of secondary nanofiller on mechanical properties and formulation optimization of HDPE/nanoclay/nanoCaCO3 hybrid nanocomposites using response surface methodology

Mechanical properties were evaluated in high-density polyethylene (HDPE) containing plate-like nanoclay (NC) and particulate nano calcium carbonate (nCaCO₃). A two-step melt mixing method was utilized to prepare nanocomposites withNC/nCaCO₃ hybrid content varying from 7 to 15 wt%. Optimization of the morphological, rheological and mechanical characteristics was carried out via Response Surface Methodology by considering nanofiller loadings and compatibilizer (PE-g-MA) content as independent variables. The findings revealed that a nanocomposite composed of 9 wt% PE-g-MA, 3.5 wt%NC, and 10 wt%nCaCO₃ was optimal. This composition exhibited 50% enhancement in Young's modulus and 8% improvement in yield strength over neat HDPE. Despite the reduced impact strength in all of the prepared nanocomposites, the incorporation ofnCaCO₃ prevented a sudden decrease in the toughness caused by the nanoclay. Further, the fracture behavior observed by scanning electron microscopy (SEM) images suggested that nCaCO₃ activated new toughening mechanisms.     

Study the effects of Cloisite15A nanoclay incorporation on the morphology and gas permeation properties of Pebax2533 polymer

In this study, mixed matrix membranes (MMMs) were prepared using commercially available poly(ether‐b‐amide) (Pebax2533) as polymer matrix and organically modified montmorillonite (OMMt) as filler with the aim of investigating their gas permeation properties. The prepared membranes were characterized by Fourier‐transform infrared (FTIR) spectroscopy, X‐ray diffraction (XRD), scanning electron microscope (SEM), thermal gravimetric analysis, and tensile strength analyses. Gas permeation properties of all the prepared membranes were evaluated at different pressures and clay loadings. Results of FTIR and SEM confirmed the appropriate adhesion between polymer and nanoclays so that no void formation was observed in the polymer/clay interface. XRD results showed that in low loading, clay dispersion occurred as exfoliated‐intercalated and at high loading as intercalated‐phase separated. Results of gas permeation test showed that by adding layered and impermeable clay particles to the polymer matrix, the permeation of soluble CO₂ gas reduced by 28% for the highest clay loading. By increasing of pressure from 2 to 6 bar, CO₂/CH₄ permselectivity increased at all nanoclay loadings. The highest CO₂/CH₄ selectivity was obtained for 6 wt % clay MMM at all pressures, while the highest CO₂/H₂ selectivity was achieved for neat polymer at 6 bar. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45302.     

Nanoclay filled soy‐based polyurethane foam

Polyurethane foam was fabricated from polymeric diphenylmethane diisocyanate (pMDI) and soy‐based polyol. Nanoclay Cloisite 30B was incorporated into the foam systems to improve their thermal stabilities and mechanical properties. Neat polyurethane was used as a control. Soy‐based polyurethane foams with 0.5–3 parts per hundred of polyols by weight (php) of nanoclay were prepared. The distribution of nanoclay in the composites was analyzed by X‐ray diffraction (XRD), and the morphology of the composites was analyzed through scanning electron microscopy (SEM). The thermal properties were evaluated through dynamic mechanical thermal analysis (DMTA). Compression and three‐point bending tests were conducted on the composites. The densities of nanoclay soy‐based polyurethane foams were higher than that of the neat soy‐based polyurethane foam. At a loading of 0.5 php nanoclay, the compressive, flexural strength, and modulus of the soy‐based polyurethane foam were increased by 98%, 26%, 22%, and 65%, respectively, as compared to those of the neat soy‐based polyurethane foam. The storage modulus of the soy‐based polyurethane foam was improved by the incorporation of nanoclay. The glass transition temperature of the foam was increased as the nanoclay loading was increased. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Evaluation of fatigue performance of filled and unfilled natural rubber/styrene-butadiene rubber composites

This paper deals with the fatigue life analysis of a blend of natural rubber (NR) and styrene-butadiene rubber (SBR) with and without nanoclay particles. Various damage parameters based on strain are investigated. A nonlinear finite element analysis is carried out by using ABAQUS. To formulate the life prediction models, the measured fatigue life is used together with various damage parameters. It is shown that all the damage parameters can estimate the fatigue lives effectively with correlation coefficients greater than 0.9. There is a good agreement between the obtained fatigue live predictions and the measured fatigue results. The effect of various parameters such as true strain and nanoparticles' loading is also investigated. The results of sensitivity analysis show that the strain has a greater effect on the variation of the rubber compounds' fatigue life. The test samples' fracture surface is assessed via scanning electron microscopy (SEM). SEM results show that as the strain increases, the test samples softly fail while the fracture surface of the nanocomposite is roughened by the addition of nanoclay.     

Morphology−performance relationship of polypropylene−nanoclay composites processed by shear controlled injection moulding

A nanoclay based masterbatch was mixed with polypropylene (PP) and injection moulded by conventional (CIM) and shear controlled orientation (SCORIM) injection moulding techniques. The aim was to correlate the morphologies induced by SCORIM and CIM processing with the thermal, mechanical and fracture performance of thick PP/nanoclay mouldings. In SCORIM, two extreme shear levels were applied by changing processing conditions. A complete characterization is reported, and statistical analysis was carried out to obtain a relationship between moulding properties. Nanoclay acted as a polymer morphology director, and in combination with SCORIM it induced the formation of the γ polymorph of PP. The nanoclay has a strong positive effect on the thermal degradation of PP under an oxidative atmosphere, due to the barrier effect of clay and the physico‐chemical adsorption of volatile degradation products on the silicates, but there were no differences between processing techniques. SCORIM samples of neat PP showed nonlinear brittle behaviour, while nanocomposites exhibited quasi‐stable behaviour induced by a large deformation capability of the skin. Although fracture initiates at practically the same loading levels, the overall propagation energy values varied with processing conditions. Statistical analysis indicates that the decrement of the core region achieved by SCORIM processing, the differences between skin and core and the PP γ phase induced by the presence of nanoclay are responsible for the toughening of SCORIM PP/nanoclay mouldings. © 2013 Society of Chemical Industry     

Effect of Nanoparticles on Mechanical and Flame-retardant Properties of Polyether-Block-Polyamide Polymer Nanocomposites

In this study, polyester elastomer-based thermoplastic (TPEE) nanocomposites were fabricated for flame-retardant applications. Small amounts of graphene and nanoclay were added to the nanocomposites to investigate their effects on the mechanical and thermal properties of the nanocomposites. The addition of a phosphorous flame-retardant additive resulted in a significant improvement of the Young’s modulus and thus yield stress in the synthesized nanocomposites as compared to those made with the virgin TPEE. There was no synergistic improvement in mechanical properties with the addition of graphene and nanoclay to the nanocomposites. However, thermal properties, mainly the heat deflection temperature and fire performance (UL-94 V0), were improved significantly by the addition of graphene and nanoclay and a synergistic effect was observed. Heat distortion temperature and thermogravimetric analysis were used to analyze the thermal properties of the nanocomposites. The UL-94 testing method was used to investigate the fire performance of the nanocomposites. Scanning electron microscopy was used to observe the polymer fracture surface morphology. The dispersion of the graphene and nanoclay particles was confirmed by transmission electron microscopy analysis.     

Effect of carbon black on properties of rubber nanocomposites

Polymer based nanocomposites were prepared using brominated poly(isobutylene‐co‐paramethylstyrene) (BIMS) rubber and octadecyl amine modified montmorillonite nanoclay. The effect of nature and loading of carbon black on these nanocomposites and the control BIMS was investigated thoroughly using X‐ray diffraction technique (XRD), Fourier transform infrared spectroscopy (FTIR), and mechanical properties. The addition of 4 parts of the modified nanoclay to 20 phr N550 carbon black filled samples increased the tensile strength by 53%. Out of the three different grades of carbon black (N330, N550, and N660), N550 showed the best effect of nanoclay. Optimum results were obtained with the 20 phr filler loading. For comparison, china clay and silica at the same loading were used. Fifty‐six and 46% improvements in tensile strength were achieved with 4 parts of nanoclay added to the silica and the china clay filled samples, respectively. N330 carbon black (20 parts) filled styrene butadiene rubber (SBR) based nanocomposite registered 20% higher tensile strength with 4 parts of the modified nanoclay. In all the above carbon black filled nanocomposites, the modulus was improved in the range of 30 to 125%. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 96: 443–451, 2005     

A new model for estimation of the thermal conductivity of polymer/clay nanocomposites

High density polyethylene– and polypropylene–clay nanocomposites are synthesized by melt blending, in which polyethylene glycol and polypropylene glycol are used as compatibilizers to increase the space of galleries. The morphology properties of nanocomposites are explored by X‐ray diffraction and transition electron microscopy. The thermal conductivity coefficient (K) of nanocomposites is also measured along with the thermal stability. A conventional model based on developed Maxwell‐Garnett formula is also established to predict the thermal conductivity of polymer/clay nanocomposites with clay loading. Morphology results indicate that two intercalated and exfoliated structures are formed. The established model satisfactorily predicts the K values of nanocomposites for low range of clay content. Thermogravimetric analysis shows remarkable thermal stability of nanocomposites with 10 wt % of clay content. The deviation of our model from experimental result for 10 wt % of clay can be attributed to the intercalated structure of layered silicates into the matrices. Although the K values do not considerably increase in 5 wt % with respect to the increase occurs for 10 wt % of clay, but it increases about 28 and 37% at 50°C for high density polyethylene– and polypropylene–clay nanocomposites, respectively. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Studies of particle dispersion in plasticized poly(vinyl chloride)/montmorillonite nanocomposites

Poly(vinyl chloride)(PVC) and dioctyl phthalate (DOP) were mixed with 5 and 10 wt % of Cloisite Na⁺, Cloisite 30B or Cloisite 93A. The obtained nanocomposites were characterized by thermal analysis using a thermogravimetric analyzer which showed that addition of 5 wt % of nanoclay to PVC increased its thermal stability in the sequence: Cloisite Na⁺< Cloisite 93A< Cloisite 30B. The electrical conductivity of these composites was studied as a function of temperatures and showed that the conductivity of PVC was enhanced upon using 5 wt % of nanoclay in the sequence: Cloisite Na⁺< Cloisite 30B < Cloisite 93A. The activation energy of interaction of PVC with nanoclay was found to be lowest for the composite containing 5 wt % of nanoclay in the same sequence. The tensile strength, elongation (%), and Young's modulus were considerably enhanced upon increasing the clay content to 5 wt % in the sequence: Cloisite Na⁺< Cloisite 93A < Cloisite 30B. X‐ray diffraction (XRD) and scanning electron microscopy (SEM) were used to study these nanocomposite structures, and it was found that the organoclay layers are homogeneously dispersed in the PVC matrix when 5 wt % of Cloisite 30B or Cloisite 93A was used. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012