A series of nanocomposite materials that consisted of emeraldine base of polyaniline and
layered montmorillonite (MMT) clay were prepared by effectively dispersing the inorganic
nanolayers of MMT clay in organic polyaniline matrix via in-situ polymerization. Organic
aniline monomers were first intercalated into the interlayer regions of organophilic clay
hosts and followed by an one-step oxidative polymerization. The as-synthesized polyaniline−clay lamellar nanocomposite materials were characterized by infrared spectroscopy, wide-angle powder X-ray diffraction, and transmission electron microscopy. Polyaniline−clay
nanocomposites (PCN) in the form of coatings with low clay loading (e.g., 0.75 wt %) on
cold-rolled steel (CRS) were found much superior in corrosion protection over those of
conventional polyaniline based on a series of electrochemical measurements of corrosion
potential, polarization resistance, and corrosion current in 5 wt % aqueous NaCl electrolyte.
The molecular weights of polyaniline extracted from PCN materials and bulk polyaniline
were determined by gel permeation chromatography (GPC). Effects of the material
composition on the gas barrier property, thermal stability, and mechanical strength of
polyaniline along with PCN materials, in the form of both fine powder and free-standing
film, were also studied by gas permeability measurements, differential scanning calorimetry,
thermogravimetric analysis, and dynamic mechanical analysis.
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