Synthesis, thermal properties and applications of polymer-clay nanocomposites

Polymer-clay nanocomposites constitute a new class of materials in which the polymer matrix is reinforced by uniformly dispersed inorganic particles (usually 10 wt.% or less) having at least one dimension in the nanometer scale. Nanocomposites exhibit improved properties when compared to pure polymer or conventional composites, such as enhanced mechanical and thermal properties, reduced gas permeability, and improved chemical stability. In this work, the synthesis of poly(methyl methacrylate) (PMMA)/clay nanocomposites is described via two methods: in situ and emulsion polymerization. The in situ technique follows a two-step process: ion-exchange of the clay to make it hydrophobic, and polymerization after dispersing the functionalized clay in the monomer. The emulsion technique combines the two steps of the in situ method into one by conducting ion-exchange and polymerization in an aqueous medium in the same reactor. The clay (montmorillonite, MMT) is functionalized with a zwitterionic surfactant, octadecyl-dimethyl betaine (C18DMB). Partially exfoliated nanocomposite, observed by transmission electron microscopy (TEM), was obtained by emulsion polymerization with 10 wt.% clay. Glass transition temperature (Tg) of this nanocomposite was 18 °C higher than pure PMMA. With the same clay content, in situ polymerization produced intercalated nanocomposite with Tg 10 °C lower than the emulsion nanocomposite. The storage modulus of partially exfoliated nanocomposite was superior to the intercalated structure and to the pure polymer. Using nanocomposite technology, novel PMMA nanocomposite gel electrolytes were synthesized exhibiting improved ionic conductivity and stable lithium interfacial resistance. Nanocomposites can also be used for gas storage and packaging applications as demonstrated by high barrier polymer-clay films.