Preparing PP/clay nanocomposites using a swelling agent

Polypropylene (PP)/clay nanocomposites (PPCN) were prepared using a swollen organoclay, which had a larger interlayer spacing than pristine organoclay. The organoclay was first treated with a swelling agent (maleic anhydride, MA) and a co-swelling agent in solution. Then, it was melt blended with PP-g-MA to generate a pre-intercalated composite (PIC). Finally, the PIC was blended with PP to obtain a PPCN, which contained small amounts of PP-g-MA. The materials were characterized using X-ray diffraction (XRD), Scanning electron microscopy, Transmission electron microscopy (TEM), and TGA. The XRD graphs showed that the basal spacing of the pristine clay treated with MA was 1.6 nm, which was larger than that of the original clay, but smaller than that of the organoclay. The XRD graphs of the organoclay treated with MA showed double peaks at 3 and 5.5°. As the ratio of MA to the organoclay increased, the peak at 5.5° decreased gradually. TEM micrographs indicated that the clay layers in the pre-intercalated blends were still stacked in an orderly manner. However, partial exfoliation of the clay layers was observed in the PPCN. The nanocomposites prepared with the aid of swelling agents contained some PP-g-MA. Good dispersion of the clay layers gave the PPCN greater thermal stability and an enhanced storage modulus, which indicated a reinforcing effect of the clay in the PP matrix. The increased T_g (derived from Dynamic mechanical analysis) of PPCN implied that the PP macromolecules were intercalated between interlayers of the silicate.