Propylene-based plastomer/nanosilica composites, with a filler content of 1-4 wt%, were prepared by a specially designed ultrasound-assisted extrusion system that was developed in our laboratory. The effects of ultrasound on the morphology, as well as the rheological and mechanical properties of the composites, were studied in this paper. In spite of slight ultrasound-induced degradation of the polymeric matrix, the results showed that the strength and elongation of the composites at break, in most cases, still improve in the presence of ultrasound because of ultrasound-induced homogeneous dispersion of nanoparticles in the polymeric matrix (as confirmed by scanning electron microscope, transmission electron microscope and differential scanning calorimetry studies). Dynamic rheological measurements also indicate that ultrasound-induced compatibilization has a more predominant role than does degradation. From dynamic mechanical measurements, it was found that ultrasound-induced degradation results in a drop in the dynamic storage modulus and glass transition temperature for composites with 4 wt% filler content, whereas ultrasound-induced compatibilization enhances their loss factor values. Polymer Journal (2011) 43, 91-96; doi:10.1038/pj.2010; published online 3 November 2010Keywords: extrusion; morphology; polymer-matrix composites (PMCs); properties; ultrasound
INTRODUCTIONIn recent years, polymer/inorganic nanocomposites, in which the size of the dispersed particles is o100 nm in at least one dimension, have attracted tremendous interest in both academic and industrial researchers. Many studies report significant improvement in the desired properties of nanocomposites, such as their mechanical properties, barrier properties, optical transparency and solvent/heat resistance, compared with those of bulk polymers or conventional microcomposites. 1-3 These improvements can be achieved at a very low loading of the inorganic component (1-10 wt%) compared with conventional filled polymers, which require high loading (25-40 wt%). These studies indicate that polymer/inorganic nanocomposites are much lighter in weight and easier to process than conventional microcomposites. 4 To a large extent, improvement in these properties depends on the morphology and dispersion of the nanoparticles in the matrix. However, obtaining a homogeneous dispersion of nanoparticles in a polymeric matrix is a very difficult task when using only a simple mixing method, because of the strong tendency of nanoparticles to agglomerate. To break down the agglomerates of nanoparticles, many researchers have attempted various routes to prepare nanostructural composites in recent years, such as the sol-gel process, 5 in situ intercalative polymerization 6,7 and in situ polymerization in the presence of nanoparticles. 8 These methods, characterized by complex polymerization and special conditions, are not only incompatible with current industrial processes such as extrusion and injection molding, but are also inapplicable for the mass production of po...