Clay-Containing Polymeric Nanocomposites

Nanocomposites are being described as the ultimate in new materials this decade. They offer potentially outstanding material performance. Clay-containing polymeric nanocomposites have now reached a commercially viable stage and are being incorporated in many new applications. It is essential that material suppliers, designers and manufacturers understand the potential and the limitations of these new products. This book is an encyclopaedic compilation of the material published to date in this exciting new field of polymer science. It describes patents, journal and conference articles and the practical experience of the author in developing and working with these new materials. All of this information is compiled in useful sections by material, processing, properties and applications. It also includes useful commercial information, such as the names of the companies who are researching and producing nanocomposites. This monograph starts with a very useful section on the different types of nanoparticles currently available. It gives details of the geometry of these particles and describes the experimental work on incorporating these particles into polymeric matrices. Clays are at by far the most advanced stages of development. There are further sections containing detailed theory of the incorporation of particles of different shapes and sizes into polymeric matrices and on how property changes may be brought about by nanoparticles. Clay has the advantage that it is a relatively cheap and abundant material. However, it is also very varied in form and chemistry: impurities can lead to degradation of nanocomposites; different types of clay will be less compatible with different types of polymer. Work has been carried out on all of these issues to look for the best clay and compatibilisers for each polymer type. This is just the start of the development process as the clay has to be dispersed to the nano-level in the matrix, involving intercalation and exfoliation. This is described in detail here together with the chemistry of the processes used. Synthetic clays are also being developed. Production methods for nanocomposites are described, for example clay can be dispersed in a melt or monomers can be mixed in and then polymerised. Most of the research to date has been carried out on thermoplastics with some on thermosets and a limited amount on elastomers. Toyota and Allied-Signal have worked on polyamides, for example, whilst Dow, Sekisui Chemical and Toyota have all taken out patents relating to polyolefins. Rheology has also been studied in depth. There is extensive data in this text including numerous tables and graphs illustrating property changes, processing attributes, chemical interactions, material types and so forth. This is a very comprehensive book and represents the forefront of the technology of Clay-Containing Polymeric Nanocomposites. Key Features… - Nanoparticle types - Clays – types and chemistry - Synthesis - Processing - Properties - Summaries of research and patent literature

Preamble PART 1 INTRODUCTION 1.1 General 1.2 NCs with Ceramic or Metallic Matrix 1.2.1 Metallic Nanoparticles in Amorphous Matrix 1.2.2 Magnetic Oxides in Silica Nanocomposites 1.2.3 Optoelectronics 1.2.4 Summary on Non-Polymeric NC 1.3 NCs with Polymeric Matrix 1.3.1 PNC Definitions 1.3.2Methods of Characterisation of CPNCs 1.3.3 Determination of PNC Properties 1.3.4 PNC Types and Methods of their Preparation 1.3.5 PNCs of Commercial Interest 1.3.6 Journals and Research Groups 1.3.7 Historical Perspective PART 2 BASIC ELEMENTS OF POLYMERIC NANOCOMPOSITE TECHNOLOGY 2.1 Nanoparticles of Interest to PNC Technology 2.1.1 General 2.1.2 Layered Nanoparticles 2.1.3 Fibrillar Nanoparticles 2.1.4 Other Nanoparticles 2.2 Clays 2.2.1 General Characteristics 2.2.2 Crystalline Clays 2.2.3 Purification of Clay 2.2.4 Reactions of Clays with Organic Substances 2.3 Intercalation of Clay 2.3.1 Introduction 2.3.2 Intercalation by Solvents and Solutions 2.3.3 Intercalation by Organic Cations 2.3.3.1 Methods of Intercalation 2.3.4 Intercalation by Organic Liquids 2.3.5 Intercalation by Monomers, Oligomers or Polymers 2.3.5.1 Intercalation of Purified Clay by Hydrophobic Compounds 2.3.6 Two-Step Intercalation 2.3.7 Intercalation by Inorganic Intercalants 2.3.8 Melt Intercalation 2.3.9 Temperature and Pressure Effects on Interlamellar Spacing 2.3.10 Layered Nanofillers, other than Montmorillonite 2.3.11 Summary of the Intercalation Methods 2.4 Exfoliation of Clays 2.4.1 Principles 2.4.2 Polymerisation in the Presence of Organoclay 2.4.3 Melt Exfoliation 2.4.4 Functional CPNC PART 3 FUNDAMENTAL ASPECTS 3.1 Thermodynamics 3.1.1 Glass Transition in Thin Films 3.1.2 Nanothermodynamics 3.1.3 Vaia’s Lattice Model for Organoclay Intercalation by Molten Polymer 3.1.4 Computations of Polymeric Brushes 3.1.5 Balazs Self-Consistent Field Approach 3.1.6 Scaling Theory for Telechelic Polymer/Clay Systems 3.1.7 Solid Surface Effects on Molecular Mobility 3.1.8 Kinetics of Polymer Intercalation 3.1.9 Pressure-Volume-Temperature Dependence for CPNC 3.2 Thermal Stability 3.2.1 Thermal Stability During Processing 3.2.2 Flame Retardancy and High Temperature Stability 3.2.3 Photo-Oxidative Stability 3.3 Rheology 3.3.1 Introduction 3.3.2 Multi-Phase Flow Behaviour – An Overview 3.3.3 Rheology and Microrheology of Disc Suspensions 3.3.4 Similarity Between CPNC and Liquid Crystal Flow 3.3.5 End-Tethered versus Non-Tethered CPNC 3.3.6 Fourier-Transform Rheology of CPNC 3.3.7 Rheology of CPNC with PA Matrix 3.3.8 Rheology of CPNC with PO Matrix 3.3.9 Foaming of CPNC 3.3.10 Rheology of CPNC with PS and Styrenics Matrix 3.3.11 Rheology of CPNC with Other Polymer Matrix Types 3.3.12 Rheology of CPNC – A Summary 3.4 Nucleation and Crystallisation 3.4.1 Introduction 3.4.2 Fundamentals of Crystallisation 3.4.3 Effects of Clay on Crystallisation of PA-6 Matrix 3.4.4 Clay Effect on Crystallisation of Other Polyamides 3.4.5 Crystallisation of PO Matrix 3.4.6 Crystallisation of PEST Matrix 3.4.7 Crystallisation of Syndiotactic PS Matrix 3.5 Mechanical Behaviour 3.5.1 Micromechanics of CPNC 3.5.2 Prediction of Tensile Strength 3.5.3 Fatigue Resistance of CPNC PART 4 TECHNOLOGY OF CLAY-CONTAINING POLYMERIC NANOCOMPOSITES 4.1 Thermoplastic CPNC 4.1.1 Polyamides (PA) 4.1.2 Polyolefins (PO) 4.1.3 General Methods of CPNC Preparation 4.1.4 Vinyl Polymers and Copolymers 4.1.5 CPNC in Water-Soluble Polymeric Matrix 4.1.6 Thermoplastic Polyesters (PEST) 4.1.7 Polycarbonate (PC) 4.1.8 Liquid Crystal Polymers (LCP) 4.1.9 Fluoropolymers 4.1.10 CPNC with High Temperature Polymers 4.1.11 Electroconductive CPNC PART 5 PERFORMANCE 5.1 Mechanical Properties 5.2 Flame Retardancy of CPNC 5.3 Permeability Control PART 6 CLOSING REMARKS 6.1 Summary 6.2 The Future 6.2.1 Composition 6.2.2 Method of Preparation 6.2.3 Characterisation and Testing PART 7 APPENDICES 7.1 General and Chemical Abbreviations 7.2 International Abbreviations for Polymers 7.3 Abbreviations for Organic Cations Used as Clay Intercalants 7.4 Notations 7.4.1 Notation Roman Letters 7.4.2 Notation – Greek Letters 7.4.3 Subscripts 7.4.4 Superscripts 7.4.5 Mathematical Symbols 7.5 Dictionary References 7.6 Companies Active in Organoclay, and/or CPNC Technology PART 8 REFERENCES References

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