Polymer/clay-based nanocomposites composite structures

Three main types of structures, which are shown in Fig. 5.3, can be obtained when a clay is dispersed in a polymer matrix (1) phase-separated structure, where the polymer chains did not intercalate the clay layers, leading to a structure similar to those of a conventional composite, (2) intercalated structure, where the polymer chains are intercalated between clay layers, forming a well ordered multilayer structure, which has superior properties to those of a conventional composite, and (3) structure exfoliated, where the clay is completely and uniformly dispersed in a polymeric matrix, maximizing the interactions polymer-clay and leading to significant improvements in physical and mechanical properties [2, 50-52]. Production of nanocomposites based on polymer/clay can be done basically in three ways (a) in situ polymerization, (b) prepared in solution and (c) preparation of the melt or melt blending [53]. 

Nanocomposites are a relatively new class of hybrid materials characterized by an ultra fine dispersion of nanofillers into a polymeric matrix. As the result of this dispersion, these materials possess unique properties, behaving much diflferentiy than conventional composites or microcomposites, and offering new technological and economical opportunities. The first studies on nanocomposites were carried out in 1961, when Blumstein performed the polymerization of vinyl monomer intercalated into montmorillonite structure. Since then, clay-based polymer nanocomposites have emerged as a new class of materials and attracted considerable interest and investment in research and development worldwide (Schaefer and Justice 2007). 

The co-continuous structure and the final rheological properties of an immiscible polymer blend are generally controlled by not only the viscoelastic and interfacial properties of the constituent polymers but also by the processing parameters. For example, the effect of plasticizer on co-continuity development in blends based on polypropylene and ethylene-propylene-diene-terpolymer (PP/EPDM), at various compositions, was studied using solvent extraction. The results showed more rapid percolation of the elastomeric component in the presence of plasticizer. However, the same fuUy co-continuous composition range was maintained, as for the non-plasticized counterparts (Shahbikian et al. 2011). It was also shown that the presence of nanoclay narrows the co-continuity composition range for non-plasticized thermoplastic elastomeric materials (TPEs) based on polypropylene and ethylene-propylene-diene-terpolymer and influences their symmetry. This effect was more pronounced in intercalated nanocomposites than in partially exfoliated nanocomposites with improved clay dispersion. It seems that the smaller, well-dispersed particles interfere less with thermoplastic phase continuity (Mirzadeh et al. 2010). A blend of polyamide 6 (PA6) and a co-polyester of... 

An alternative to in situ polymerization involves direct intercalation of macromolecules into layered structures. Silicates are most often used. The insertion of polymer molecules into layered host lattices is of interest from different points of view. First, this insertion process leads to the construction of organic-inorganic polylayered composites. Second, the intercalation physical chemistry by itself and the role intercalation plays in the gain of electronic conductivity are of interest. This becomes important in the construction of reversible electrodes " or when improving the physicomechanical properties of nylon-layered silicate nanocomposites, hybrid epoxide clay composites," and nanomaterials based on hectorite and polyaniline, polythiophene or polypyrrole. ... 

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