The dispersion of clay in a polymer matrix is influenced by two factors: the choice of organic treatment for the clay and the processing or mixing method. Maximum benefits are achieved when the platelets are well dispersed or exfoliated. Exfoliated nanocomposites are formed when the individual clay layers break off the agglomerated particles or tactoids and are either randomly dispersed in the polymer (a disordered nanocomposite) or left in an ordered array. It is suggested that size reduction of clay particles and platelet delamination occur by erosion or surface peeling. A model based on the classical theories of interparticle interactions was formulated for the exfoliation of the clay platelets in a polymer matrix. The model involves the estimation of the binding energy and the adhesive force between the platelets in a clay particle, which indicate the forces required for breaking apart or delamination of clay particles. Then, the shear force required for breakup or delamination of the tactoids is estimated and compared to the hydrodynamic shear forces available during processing. POLYM
INTRODUCTIONPolymer/clay nanocomposites are materials composed of a polymer matrix and nanometer size clay particles. They exhibit significant improvements in tensile modulus and strength and reduced permeability to gases and liquids, in comparison with the pure polymer. These property improvements can be realized, while retaining clarity of the material with a little increase in density, since the typical clay loading is 2-5 wt%. It is well known that some polymers interact with montmorillonite and that the clay surface can act as an initiator for polymerization [1,2]. However, clay/polyamide-6 (PA-6) nanocomposites were commercialized mainly after practical methods were developed for appropriate dispersion of the clays at the nanometer scale [3].The first step in achieving nanoscale dispersion of clays in polymers is to expand the galleries and to match the polarity of the polymer or monomer, so that it will intercalate between the layers [4]. This is done by exchanging an inorganic cation, generally sodium cation present in the clay, with an organic cation of a quaternary ammonium compound. The larger organic cations swell the layers and increase the hydrophobic (or organophilic) properties of the clay [5], resulting in an organically modified clay. The organically modified clay can then be intercalated with polymer by several routes. Highly polar polymers, such as polyamides and polyimides, are more easily intercalated than nonpolar polymers, such as polypropylene and polyethylene [6,7]. Melt intercalation involves mixing the clay and polymer melt, with or without shear. Nanocomposites can have several structures. Intercalated nanocomposites usually appear as tactoids with expanded interlayer spacing, but the clay basal spacing remains in the few nanometer range. Exfoliated nanocomposites are formed when the individual clay layers break off the tactoid and are either randomly dispersed in the polymer (a disordered nanocom...