Preparation and mechanical properties of exfoliated mica-polyamide 6 nanocomposites using sericite mica

A new mica/polyamide 6 (PA6) nanocomposite was formed by exfoliation of a mica, potassium sericite (K⁺-SE). The powder sample was separated through an air-classifier into D₅₀:6.0 μm (median particle diameter), D₁₀:3.5 μm, and D₉₀:9.5 μm. The K⁺-SE was modified with a dodecylammonium salt (DDA) by ion exchange at 70 °C for four days. The resulting organically modified SE was melt-kneaded with PA6 in a twin-screw kneader at 260 °C. In order to characterize the nanocomposite morphology, X-ray diffraction and transmission electron microscopy were used. Differential scanning calorimetry and mechanical property measurements were also carried out. The morphology of the nanocomposite revealed mica nanolayers with very high aspect ratios; that is, at levels about two times greater than that of conventional exfoliated clay-polymer nanocomposites. A small amount of organically modified SE with 2.1 mass% silicate was sufficient to improve the flexural properties and heat distortion temperature of the nanocomposite. However, overall mechanical properties were not completely improved, because the shearing stress induced during exfoliation of the silicate layers resulted in inhomogenous dispersion of silicate platelets in the matrix. The present study indicates that three factors, degree of exfoliation, aspect ratio and dispersion homogeneity of silicate platelets, play an important role for the development of high performance nanocomposites.