Effect of the surfactant coverage on the preparation of polystyrene–clay nanocomposites prepared by melt intercalation

The melt intercalation of polystyrene (PS) into organoclay with variation in the degree of surfactant coverage by melt intercalation was investigated. The surface coverage of the organoclay was found to play a major role in controlling the type of the final composites formation. Two major types of composites were found depending upon the surface treatment of the organoclay. These are conventional composites and intercalated nanocomposites. At the high degree of the clay's surface coverage, the conventional composite was obtained. It is characterized by the micron size aggregate of the organoclay particle. An intercalated nanocomposite was observed in the organoclay with a lower surface coverage. The organoclay is dispersed into a smaller stack along with the intercalation of polystyrene into the organoclay interlayer. This is originated from the affinity between the organoclay surface and a molten polystyrene.