Polymer/clay/wood nanocomposites: The effect of incorporation of nanoclay into the wood/polymer composites

Thermoplastic composites play an important role in our society. The uses of these composites range from cookware to components for the space shuttle. In recent years, researchers at Toyota developed numerous methods of preparation for composites made from olefins and inorganic fillers such as clay and calcium carbonate. Wood fibers have been used as reinforcing filler in polymer matrices for the past several decades. The advantages of using wood fibers as reinforcing fillers are: the low cost of the fibers (or flour), low density, and resistance to breakage. The disadvantage of using wood as a filler is the thermal instability of wood above 200 °C. The majority of thermoplastics exhibit melting points between 160 and 220 °C, which is in the range of thermal decomposition of wood.; Nanoclay was first successfully used as a filler in polyolefin materials by the Toyota research team in early 90s. It was found that the addition of a small amount (< 5 wt.%) of nanoclay increased the mechanical properties of a Nylon-6 matrix dramatically. Since Nylon-6 is a hydrophilic material no compatibilizer was necessary to exfoliate the nanoclay. The use of compatibilizers such as maleic modified polyethylenes (MAPEs) is necessary upon addition of nanoclay to a hydrophobic polyolefin systems such polyethylene (PE) or polypropylene (PP).; Few researchers have attempted to reinforce the polymer matrix via the use of the nanoclay for use as a matrix in wood/polymer composites. High molecular weight and low molecular weight MAPEs have been used to enhance the bonding between the nanoclay and the polymer matrix as well as between the wood flour and the polymer matrix.; The effects of combinations of the high and low molecular weight MAPEs on the mechanical and thermal properties of polymer/clay nanocomposites (PCNs) and of wood/polymer/clay composites (WPCs) were investigated. The effects of adding nanoclay to wood/polymer systems on the mechanical and thermal properties of the composites were also investigated. A model based on the Halpin-Tsai model was developed that predicts the (Young's) modulus-temperature relationship of the composites based on discontinuous fillers.; It was found that the molecular weight of the compatibilizer significantly affects the exfoliation/dispersion of the nanoclay within the polymer matrix. A compatibilizer containing a high Mw fraction based on high density polyethylene (HDPE) and a low Mw fraction based on linear low density polyethylene (LLDPE) was found to be the most effective at enhancing the thermal and mechanical properties of PCNs and WPCs. A compatibilizer containing greater than 60 wt.% high Mw fraction resulted in a 30% increase of the modulus and a 15°C increase of the heat deflection temperature (HDT).; The addition of the nanoclay had a detrimental effect on the moduli of PCNs and WPCs when a low Mw compatibilizer based on LLDPE was used. The moduli of these composites increased with increasing high Mw content of the compatibilizer and increasing nanoclay content. The addition of the nanoclay to wood/polymer composites resulted in an increased modulus of elasticity and HDT of these composites.; The developed model quantitatively predicts the modulus-temperature relationship of the fiber containing composites. It was found that the modulus of the composites varies linearly with temperature and was highly dependent on the exfoliation of the nanoclay within the polymer matrix.