Dispersion quality and polymer-filler interaction are important factors in determining the final properties of polymer nanocomposites. Surface energy of nanocrystalline cellulose (NCC) and some polymers (polypropylene, PP, and polylactic acid, PLA) was measured at room and high temperatures. NCC had higher polarity and surface energy than PP and PLA at room temperature but had a lower surface energy at higher temperatures. The effect of surface modification with alkenyl succinic anhydride (ASA) on NCC surface energy at room and high temperature was studied. Total surface energy of NCC was lowered after surface modification. Thermodynamic work of adhesion for PP/NCC and PLA/NCC was lowered by NCC surface modification. A thermodynamic analysis is proposed to estimate the dispersion energy, based on surface energy measurements at room and high temperatures. Also, a dispersion factor is defined to provide a quantitative indication of the dispersibility of nanoparticles in a polymer matrix under various conditions. The required dispersion energy was reduced by lowering the interfacial tension. On the other hand, it increased as the quality of NCC dispersion (i.e., the nanoparticle surface area) in the system was improved. Surface modification of NCC with ASA had a negative effect on the compatibility between NCC and PLA, whereas it had a positive influence on compatibility between PP and NCC.

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Polypropylene (PP) nanocomposites containing spray-dried cellulose nanocrystals (CNC), freeze-dried CNC, and spray-freeze-dried CNC (CNCSFD) were prepared via melt mixing in an internal batch mixer. Polarized light, scanning electron, and atomic force microscopy showed significantly better dispersion of CNCSFD in PP/CNC nanocomposites compared with the spray-dried and freeze-dried CNCs. Rheological measurements, including linear and nonlinear viscoelastic tests, were performed on PP/CNC samples. The microscopy results were supported by small-amplitude oscillatory shear tests, which showed substantial rises in the magnitudes of key rheological parameters of PP samples containing CNCSFD. Steady-shear results revealed a strong shear thinning behavior of PP samples containing CNCSFD. Moreover, PP melts containing CNCSFD exhibited a yield stress. The magnitude of the yield stress and the degree of shear thinning behavior increased with CNCSFD concentration. It was found that CNCSFD agglomerates with a weblike structure were more effective in modifying the rheological properties. This effect was attributed to better dispersion of the agglomerates with the weblike structure. Dynamic mechanical analysis showed considerable improvement in the modulus of samples containing CNCSFD agglomerates. The percolation mechanical model with modified volume percolation threshold and filler network strength values and the Halpin-Kardos model were used to fit the experimental results.

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