Ultraviolet-curable nanocomposites containing organically modified nanoclays were prepared to serve as barrier coatings against oxygen and water permeation. A novel in situ synthesis technique was used to produce well-dispersed clays in an unsaturated polyester polymer before crosslinking. The in situ dispersion route was compared with nanocomposites prepared by mixing and sonication for several levels of nanoclay loading (1, 2, 5, and 10 wt %). The comparison of nanocomposite properties prepared from each processing method demonstrated that the in situ preparation technique led to better clay disper-sion as verified by transmission electron microscopy. The in situ route for nanoclay dispersion produced nanocomposites with lower water vapor transmission and permeability compared with the sonicated dispersion method. The impact on cure characteristics, mechanical properties, thermal stability, and optical clarity of the nanocomposites were also compared.

UV-curable nanocomposites based on donor-acceptor crosslinking chemistry were prepared containing organically modified montmorillonites. The coatings were characterized for thermal, mechanical, and morphological properties. X-ray diffraction and transmission electron microscopy showed that nanocomposites were formed in all samples. Results showed that an increase in the percentage of clay caused an increased modulus and glass-transition temperature. It was also seen that tensile modulus showed dramatic improvement when compared with the unmodified polyester sample. Real time IR kinetic data showed that higher conversions were obtained at higher clay loadings. Pendulum hardness values and tensile modulus values showed different trends in properties depending on the combination of polymer matrix and organomodification.

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