Melt-state rheology, solid-state mechanical properties and microstructure of polymer-clay nanocomposites

Polymer/clay nanocomposites have the potential usefulness in industrial applications such as automotive and packaging due to their strong, light-weight and inexpensive properties. However, to respond to needs of various applications it is crucial to understand the crystallization and rheological properties of these materials. Our initial hypothesis was that the processing conditions such as shear rate, shear strain and temperature affect the crystallization kinetics of intercalated polypropylene nanocomposites. Another hypothesis was that the compatibilizer, PP-MA, affects the role of the nucleating agent, sodium benzoate. The final hypothesis was that the rheological properties of nanocomposites depend on the degree of clay dispersion. By means of time-resolved small-angle light scattering, we were able to demonstrate that clay enhances the crystallization kinetics in nanocomposites and its result differs significantly from that of pure polypropylene. Characteristic crystallization times are extracted from the time evolution of integral measures of the angularly dependent parallel polarized and cross polarized light scattering intensity. Flow acceleration of crystallization kinetics has been observed for the polymer nanocomposites at applied strain rates for which flow has only modest effect on polypropylene crystallization. Furthermore, we were able to conclude that the addition of the nucleating agent sodium benzoate in the presence of polypropylene grafted maleic anhydride is not effective in accelerating crystallization. The rheological properties of two types of polypropylene/clay nanocomposites, with different degrees of clay dispersion have been measured in both linear and non-linear viscoelastic regime. In the linear viscoelastic regime, the storage and loss modulus of nanocomposites increases when clay loading increases. The storage and loss modulus of unsonicated nanocomposites are higher than the sonicated ones because the ultrasonic processing alters the structure of clay and polymer blend in sonicated nanocomposite. Non-linear rheology addresses the possible structure of particulate domains of clays in polymers. From this research, we demonstrated the possible effect of clay and compatibilizer on the crystallization kinetics and the effect of structure of clay and polymer matrix on rheological properties. To understand how clay enhances the mechanical properties, we still need to investigate where the clay actually resides and how the polymer crystallite forms.