Effective reinforcement of carbon nanotubes in polypropylene matrices

Surface Response Analysis for the Optimization of Mechanical and Thermal Properties of Polypropylene Composite Drawn Fibers with Talc and Carbon Nanotubes

A large portion of the produced Polypropylene (PP) is used in the form of fibers. In this industrially oriented study, the development of composite PP drawn fibers was investigated. Two types of fillers were used (ultra-fine talc and single-wall carbon nanotubes). Optimization of the thermal and mechanical properties of the produced composite drawn fibers was performed, based on the Box-Behnken design of experiments method (surface response analysis). The effect of additives, other than the filler, but typical in industrial applications, such as an antioxidant and a common compatibilizer, was investigated. The drawing ratio, the filler, and the compatibilizer or the antioxidant content were selected as design variables, whereas the tensile strength and the onset decomposition temperature were set as response variables. Fibers with very high tensile strength (up to 806 MPa) were obtained. The results revealed that the maximization of both the tensile strength and the thermal stability was not feasible for composites with talc due to multiple interactions among the used additives (antioxidant, compatibilizer, and filler). Additionally, it was found that the addition of talc in the studied particle size improved the mechanical strength of fibers only if low drawing ratios were used. On the other hand, the optimization targeting maximization of both tensile strength and thermal stability was feasible in the case of SWCNT composite fibers. It was found that the addition of carbon nanotubes improved the tensile strength; however, such improvement was rather small compared with the tremendous increase of tensile strength due to drawing.

Optimization of Thermal and Mechanical Properties of Polypropylene-Wollastonite Composite Drawn Fibers Based on Surface Response Analysis

The thermal and mechanical properties of polypropylene-wollastonite composite drawn fibers were optimized via experiments selected with the Box-Behnken approach. The drawing ratio, the filler and the compatibilizer content were chosen as design variables, while the tensile strength, the melting enthalpy and the onset decomposition temperature were set as response variables. Drawn fibers with tensile strength up to 535 MPa were obtained. Results revealed that the drawing ratio is the most important factor for the enhancement of tensile strength, followed by the filler content. All the design variables slightly affected the melting temperature and the crystallinity of the matrix. Also, it was found that the addition of polypropylene grafted with maleic anhydride as compatibilizer has a multiple effect on the final properties, i.e., it induces the dispersion of both the antioxidant and the filler, tending to increase thermal stability and tensile strength, while, on the same time, deteriorates mechanical and thermal properties due to its lower molecular weight and thermal stability. Such behavior does not allow for simultaneous maximization of thermal stability and tensile strength. Optimization based on a compromise, i.e., targeting maximization of tensile strength and onset decomposition temperature higher than 300 °C, yields high desirability values and predictions in excellent agreement with verification experiments.

Structure-Function Relationships of Nanocarbon/Polymer Composites for Chemiresistive Sensing: A Review

Composites of organic compounds and inorganic nanomaterials provide novel sensing platforms for high-performance sensor applications. The combination of the attractive functionalities of nanomaterials with polymers as an organic matrix offers promising materials with tunable electrical, mechanical, and chemisensitive properties. This review mainly focuses on nanocarbon/polymer composites as chemiresistors. We first describe the structure and properties of carbon nanofillers as reinforcement agents used in the manufacture of polymer composites and the sensing mechanism of developed nanocomposites as chemiresistors. Then, the design and synthesizing methods of polymer composites based on carbon nanofillers are discussed. The electrical conductivity, mechanical properties, and the applications of different nanocarbon/polymer composites for the detection of different analytes are reviewed. Lastly, challenges and the future vision for applications of such nanocomposites are described.

Influence of the Solidification Process on the Mechanical Properties of Solid-State Drawn PCL/Sepiolite Nanocomposite Tapes

In this research, poly(ε-caprolactone) (PCL) was melt-mixed with sepiolite nanoclays in a twin-screw extruder. In a subsequent step, the extruded films were drawn in the solid state to highly oriented nanocomposite films or tapes. A twin-screw extruder equipped with a Sultzer mixer for improved mixing in combination with a bench top drawing unit was used to prepare oriented nanocomposite tapes of different sepiolite loading and draw ratios. In order to study the influence of the solidification step on the drawability of the materials, different cooling procedures were applied prior to drawing. Optical microscopy images showed that slow or fast solidification using different chill rolls settings (open or closed) for the cast films resulted in different morphological conditions for subsequent drawing. The addition of sepiolite nanofillers led to nucleation and faster crystallization kinetics and oriented tapes which deformed by homogenous deformation rather than necking. The addition of sepiolite significantly improved the mechanical properties of both undrawn and drawn PCL tapes and Young’s modulus (1.5 GPa) and tensile strength (360 MPa) for composites based on 4 wt% sepiolite were among the highest ever reported for PCL nanocomposites. Interestingly, samples cooled with open chill rolls (slow crystallization) showed the highest modulus while solidification with closed rolls (fast crystallization) showed the highest tensile strength after drawing.

The Influence of Melt-Mixing Conditions and State of Dispersion on Crystallisation, Rheology and Mechanical Properties of PCL/Sepiolite Nanocomposites

It is generally accepted that the benefit of anisotropic nanofiller addition is strongly dependent on the state of the dispersion of these fillers in a polymer matrix. In this paper the influence of melt-compounding conditions on the dispersion of a needle-like clay, i. e. sepiolite, in poly(∊-caprolactone) (PCL) is investigated. The crystallisation behavior as well as the rheological and mechanical properties of PCL/sepiolite nanocomposites with filler contents up to 5 wt.% are studied. By changing the screw speed during melt-mixing in a micro-compounder, the state of dispersion was varied, with the higher speed leading to better dispersion and breakdown of the sepiolite agglomerates or bundles. Rheometry showed that better dispersed nanocomposites displayed an increase in viscosity due to network formation at slightly higher filler loadings. Likewise, better dispersed composites showed a modest increase in crystallisation temperature at low filler content, accompanied by a decrease in both nucleation efficiency and degree of crystallisation at higher loadings. Better dispersed nanocomposite systems also showed superior mechanical properties, particularly at higher filler loadings. However, overall the reinforcing efficiency of sepiolite in all nanocomposites was relatively low. This was mainly a consequence of the relatively low filler aspect ratio and the simultaneous breakup of sepiolite needles together with a breakdown of bundles during compounding.

Filler reinforcement in cross-linked elastomer nanocomposites: insights from fully atomistic molecular dynamics simulation

Using a fully atomistic model, we perform large-scale molecular dynamics simulations of sulfur-cured polybutadiene (PB) and nanosilica-filled PB composites. A well-integrated network without sol fraction is built dynamically by cross-linking the coarse-grained precursor chains in the presence of embedded silica nanoparticles. Initial configurations for subsequent atomistic simulations are obtained by reverse mapping of the well-equilibrated coarse-grained systems. Based on the concept of "maximally inflated knot" introduced by Grosberg et al., we show that the networks simulated in this study behave as mechanically isotropic systems. Analysis of the network topology in terms of graph theory reveals that mechanically inactive tree-like structures are the dominant structural components of the weakly cross-linked elastomer, while cycles are mainly responsible for the transmission of mechanical forces through the network. We demonstrate that quantities such as the system density, thermal expansion coefficient, glass transition temperature and initial Young's modulus can be predicted in qualitative and sometimes even in quantitative agreement with experiments. The nano-filled system demonstrates a notable increase in the glass transition temperature and an approximately two-fold increase in the nearly equilibrium value of elastic modulus relative to the unfilled elastomer even at relatively small amounts of filler particles. We also examine the structural rearrangement of the nanocomposite subjected to tensile deformation. Under high strain-rate loading, the formation of structural defects (microcavities) within the polymer bulk is observed. The nucleation and growth of cavities in the post-yielding strain hardening regime mainly take place at the elastomer/nanoparticle interfaces. As a result, the cavities are concentrated just near the embedded nanoparticles. Therefore, while the silica nanofiller increases the elastic modulus of the elastomer, it also creates a more defective structure of higher energy in comparison with the unfilled network.

Confine Clay in an Alternating Multilayered Structure through Injection Molding: A Simple and Efficient Route to Improve Barrier Performance of Polymeric Materials

Various methods have been devoted to trigger the formation of multilayered structure for wide range of applications. These methods are often complicated with low production efficiency or require complex equipment. Herein, we demonstrate a simple and efficient method for the fabrication of polymeric sheets containing multilayered structure with enhanced barrier property through high speed thin-wall injection molding (HSIM). To achieve this, montmorillonite (MMT) is added into PE first, then blended with PP to fabricate PE-MMT/PP ternary composites. It is demonstrated that alternating multilayer structure could be obtained in the ternary composites because of low interfacial tension and good viscosity match between different polymer components. MMT is selectively dispersed in PE phase with partial exfoliated/partial intercalated microstructure. 2D-WAXD analysis indicates that the clay tactoids in PE-MMT/PP exhibits an uniplanar-axial orientation with their surface parallel to the molded part surface, while the tactoids in binary PE-MMT composites with the same overall MMT contents illustrate less orientation. The enhanced orientation of nanoclay in PE-MMT/PP could be attributed to the confinement of alternating multilayer structure, which prohibits the tumbling and rotation of nanoplatelets. Therefore, the oxygen barrier property of PE-MMT/PP is superior to that of PE-MMT because of increased gas permeation pathway. Comparing with the results obtained for PE based composites in literature, outstanding barrier property performance (45.7% and 58.2% improvement with 1.5 and 2.5 wt % MMT content, respectively) is achieved in current study. Two issues are considered responsible for such improvement: enhanced MMT orientation caused by the confinement in layered structure, and higher local density of MMT in layered structure induced denser assembly. Finally, enhancement in barrier property by confining impermeable filler into alternating multilayer structure through such simple and efficient method could provide a novel route toward high-performance packaging materials and other functional materials require layered structure.

Towards tunable sensitivity of electrical property to strain for conductive polymer composites based on thermoplastic elastomer

The use of conductive polymer composites (CPCs) as strain sensors has been widely investigated and various resistivity-strain sensitivities are desirable for different applications. In this study, the use of mixed carbon fillers and functionalized carbon nanotubes was demonstrated to be vital for preparing thermoplastic polyurethane (TPU)-based strain sensors with tunable sensitivity. To understand the strain sensing behavior, we carried out scanning electron microscopy (SEM), Raman spectroscopy, wide-angle X-ray diffraction (WAXD), mechanical test, and rheology-electrical measurement. Hybrid fillers of multi-walled carbon nanotubes (MWNTs) and carbon black (CB) could reduce the entanglement in conductive network structure, thus increase the resistivity-strain sensitivity. Furthermore, incorporation of additional functionalized MWNTs in the CPCs could enhance the interfacial interaction between nanofillers and TPU, leading to further increase in sensitivity. Through such a simple method, strain sensors could be efficiently fabricated with large strain-sensing capability (strain as large as 200%) and a wide range of strain sensitivity (gauge factor ranging from 5 to 140238). Finally, the exponential revolution of resistive response to strain was fitted with a model based on tunneling theory by Simmons. It was observed that the change in tunneling distance and the number of conductive pathways could be accelerated significantly by adjusting conductive network structure and interfacial interaction. This study provides a guideline for the preparation of high-performance CPC strain sensors with a large range of resistivity-strain sensitivity.

Liquid-State and Solid-State Properties of Nanotube/Polypropylene Nanocomposites Elaborated via a Simple Procedure

Non-modified Multiwalled Carbon Nanotubes (MWCNT) and polypropylene (PP) in absence of compatibilizer have been chosen to elaborate MWCNT/PP nanocomposites using a simple melt-mixing dispersing method. Calorimetry results indicate little effect of MWCNTs on crystallinity of PP, revealing not much interaction between nanotubes and PP chains, which is compatible with the employed manufacturing procedure. In any case, a hindering of polymer chains motion by MWCNTs is observed in the molten state, using oscillatory flow experiments, and a rheological percolation threshold is determined. The percolation limit is not noticed by Pressure-Volume-Temperature (PVT) measurements in the melt, because this technique rather detects local motions. Keeping the nanocomposites in the molten state provokes an electrical conductivity increase of several orders of magnitude, but on ulterior crystallization, the conductivity decreases, probably due to a reduction of the ionic conductivity. For a concentration of 2% MWCNTs, in the limit of percolation, the conductivity decreases considerably more, because percolation network constituted in the molten state is unstable and is destroyed during crystallization.