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Intercalated nanocomposites of modified montmorillonite clays in a glassy epoxy were prepared by crosslinking with commercially available aliphatic diamine curing agents. These materials are shown to have improved Young's modulus but corresponding reductions in ultimate strength and strain to failure. The results were consistent with most particulate‐filled systems. The macroscopic compressive behavior was unchanged, although the failure mechanisms in compression varied from the unmodified samples. The fracture toughness of these materials was investigated and improvements in toughness values of 100% over unmodified resin were demonstrated. The fracture‐surface topology was examined using scanning electron and tapping‐mode atomic force microscopies and shown to be related to the clay morphology of the system. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 1137–1146, 2001

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Microcellular polystyrene foams have been prepared using supercritical carbon dioxide as the foaming agent. The cellular structures resulting from this process have been shown to have a significant effect on the corresponding mechanical properties of the foams. Compression tests were performed on highly expanded foams having oriented, anisotropic cells. For these materials an anisotropic foam model can be used to predict the effect of cell size and shape on the compressive yield stress. Beyond yield, the foams deformed heterogeneously under a constant stress. Microstructural investigations of the heterogeneous deformation indicate that the dominant mechanisms are progressive microcellular collapse followed by foam densification. The phenomenon is compared to the development of a stable neck commonly observed in polymers subjected to uniaxial tension, and a model that describes the densification process is formulated from simple energy balance considerations.

PMMA-layered silicate intercalated nanocomposites are synthesized using supercritical carbon dioxide (scCO2) to produce ordered materials with significant levels of reinforcement. The scCO2 is used to homogeneously distribute monomer as well as act as a low-viscosity solvent for MMA polymerization. This route allows for synthesis of nanocomposites containing significant levels of organically modified layered silicates (OMLS). Below 40 wt % OMLS, the intercalated nanocomposites exhibit a d spacing commensurate with dimensions of the fully extended surfactant chains. Above 40 wt % OMLS, the composite volume is saturated with inorganic material, and the d spacing decreases to homogeneously distribute the polymer volume. A model for estimating this transition concentration is presented. At concentrations approaching the homogeneously intercalated morphology, the basic mechanical and physical properties of the composite are investigated.