Processing techniques for bio-based unsaturated-polyester/clay nanocomposites: Tensile properties, efficiency, and limits

Bio-based clay/polymer nanocomposites using blends of styrene-based unsaturated polyester and epoxidized methyl soyate were manufactured using solvent-based processing techniques. Four methods were evaluated to assess limitations related to solvent removal and incorporation of high clay and bio-resin content. Nanocomposite characterization was performed using electron microscopy and tensile tests. Solvent type, bio-resin addition sequence, and sonication energy were the key parameters governing processing efficiency and composite quality. Processes with bio-resin added after solvent removal show promise for the incorporation of high bio-resin and nanoclay contents. Use of acetone as a solvent with bio-resin added after solvent removal led to nanocomposites with good nanoclay dispersion and exfoliation, and high tensile modulus. Direct sonication in the base resin diluted with styrene led to enhanced and balanced gains in stiffness and toughness.