Polymeric nanocomposites: Compounding and performance

Polymeric nanocomposites (PNC) are binary mixtures of strongly interacting, inorganic platelets dispersed in a polymeric matrix. For full exfoliation, the thermodynamic miscibility is required. There are three basic methods of organically-modified clay dispersion that might result in PNC: (1) in polymer solution (followed by solvent removal), (2) in a monomer (followed by polymerization), and (3) in molten polymer (compounding). Most commercial PNC are produced by the second method, but it is the third one that has the greatest promise for the plastics industry. Similarly as during the manufacture of polymer blends, the layered silicates must be compatibilized by intercalation with organic salts and/or addition of functionalized macromolecules. Compounding affects the kinetics of dispersion process, but rarely the miscibility. Melt compounding is carried out either in a single-screw (SSE) or a twin-screw extruder (TSE). Furthermore, an extensional flow mixer (EFM) might be attached to an extruder. Two versions of EFM were evaluated: (1) designed for polymer homogenization and blending, and (2) designed for dispersing nano-particles. In this review, the dispersion of organoclay in polystyrene (PS), polyamide-6 (PA-6) or in polypropylene (PP) is discussed. The PNC based on PS or PA-6 contained two components (polymer and organoclay), whereas those based on PP in addition had a compatibilizer mixture of two maleated polypropylenes. Better dispersion was found compounding PNC's in a SSE+ EFM than in TSE with or without EFM. The mechanical performance (tensile, flexural and impact) was examined.