Strategies for the synthesis of thermoplastic polymer nanocomposite materials with high inorganic filling fraction

Enhancing the Performance of Rubber with Nano ZnO as Activators

The vulcanization of rubber is a chemical process to improve the mechanical properties by cross-linking unsaturated polymer chains. Zinc oxide (ZnO) acts as an activator, boosting the rubbers' sulfur vulcanization. Maintaining the level of ZnO content in the rubber compounds as low as possible is desirable, not only for economic reasons but also to reduce the environmental footprint of the process. In this contribution, octylamine (OA) capped ZnO nanoparticles (5 nm diameter), prepared through a thermal decomposition method, were demonstrated to be efficient activators for the sulfur vulcanization of natural rubber, enabling the reduction of the required amount of ZnO as compared to commercial systems. The effect of different ZnO activators (OA capped ZnO/commercial indirect process ZnO) on the curing characteristics, cross-linking densities, and mechanical performance, as well as the thermal behavior of rubber compounds, were investigated. Compared to the commercial indirect process ZnO, OA capped ZnO nanoparticles not only effectively enhanced the curing efficiency of natural rubber but also improved the mechanical performance of the composites after vulcanization. This was interpreted as, by applying the OA capped ZnO nanoparticles, the ZnO levels in rubber compounding were significantly reduced under the industrial vulcanization condition (151 °C, 30 min).

Photocatalytic Active Mesoporous Carbon/ZnO Hybrid Materials from Block Copolymer Tethered ZnO Nanocrystals

Severe water pollution issues present an important contemporary challenge that drives the development and advancement of efficient and environmentally benign photocatalysts that enable the degradation of pollutants upon visible light irradiation. One example is zinc oxide/carbon (ZnO/C) hybrid materials that have been shown to be effective photocatalysts. To maximize the effectiveness of ZnO/C hybrids, materials with high accessible surface area of ZnO are required. Here, a novel strategy is presented to enable the synthesis of fine dispersions of ZnO nanoparticles within a porous carbon matrix. The synthesis entails the grafting of ZnO nanparticles with polystyrene-b-poly(styrene-co-acrylonitrile) (PS-b-PSAN) block copolymer and subsequent pyrolysis of the material under inert gas (N₂) atmosphere. During the pyrolysis process, the PS block effectively prevents agglomeration of ZnO particles, thus resulting in a fine dispersion of ZnO nanocrystals within a prorous C matrix. Materials are found to exhibit a dye adsorption capacity of 125 mg g^-1 (from a methylene blue aqueous solution with a concentration of 305 mg L^-1) and dye degradation rate constant of 0.021 min^-1. The significant increase of effective surface area and degradation efficacy (as compared to ZnO/C synthesized by the pyrolysis of binary PSAN/ZnO blends) is rationalized as a consequence of the increased porosity that promotes dye adsorption and transport within the hybrid material.

Analysis of the Efficiency of Surfactant-Mediated Stabilization Reactions of EGaIn Nanodroplets

A methodology based on light scattering and spectrophotometry was developed to evaluate the effect of organic surfactants on the size and yield of eutectic gallium/indium (EGaIn) nanodroplets formed in organic solvents by ultrasonication. The process was subsequently applied to systematically evaluate the role of headgroup chemistry as well as polar/apolar interactions of aliphatic surfactant systems on the efficiency of nanodroplet formation. Ethanol was found to be the most effective solvent medium in promoting the formation and stabilization of EGaIn nanodroplets. For the case of thiol-based surfactants in ethanol, the yield of nanodroplet formation increased with the number of carbon atoms in the aliphatic part. In the case of the most effective surfactant system-octadecanethiol-the nanodroplet yield increased by about 370% as compared to pristine ethanol. The rather low overall efficiency of the reaction process along with the incompatibility of surfactant-stabilized EGaIn nanodroplets in nonpolar organic solvents suggests that the stabilization mechanism differs from the established self-assembled monolayer formation process that has been widely observed in nanoparticle formation.

Transparent and High Refractive Index Thermoplastic Polymer Glasses Using Evaporative Ligand Exchange of Hybrid Particle Fillers

Development of high refractive index glasses on the basis of commodity polymer thermoplastics presents an important requisite to further advancement of technologies ranging from energy efficient lighting to cost efficient photonics. This contribution presents a novel particle dispersion strategy that enables uniform dispersion of zinc oxide (ZnO) particles in a poly(methyl methacrylate) (PMMA) matrix to facilitate hybrid glasses with inorganic content exceeding 25% by weight, optical transparency in excess of 0.8/mm, and a refractive index greater than 1.64 in the visible wavelength range. The method is based on the application of evaporative ligand exchange to synthesize poly(styrene-r-acrylonitrile) (PSAN)-tethered zinc oxide (ZnO) particle fillers. Favorable filler-matrix interactions are shown to enable the synthesis of isomorphous blends with high molecular PMMA that exhibit improved thermomechanical stability compared to that of the pristine PMMA matrix. The concurrent realization of high refractive index and optical transparency in polymer glasses by modification of a thermoplastic commodity polymer could present a viable alternative to expensive specialty polymers in applications where high costs or demands for thermomechanical stability and/or UV resistance prohibit the application of specialty polymer solutions.

Surface-Initiated Controlled Radical Polymerization: State-of-the-Art, Opportunities, and Challenges in Surface and Interface Engineering with Polymer Brushes

The generation of polymer brushes by surface-initiated controlled radical polymerization (SI-CRP) techniques has become a powerful approach to tailor the chemical and physical properties of interfaces and has given rise to great advances in surface and interface engineering. Polymer brushes are defined as thin polymer films in which the individual polymer chains are tethered by one chain end to a solid interface. Significant advances have been made over the past years in the field of polymer brushes. This includes novel developments in SI-CRP, as well as the emergence of novel applications such as catalysis, electronics, nanomaterial synthesis and biosensing. Additionally, polymer brushes prepared via SI-CRP have been utilized to modify the surface of novel substrates such as natural fibers, polymer nanofibers, mesoporous materials, graphene, viruses and protein nanoparticles. The last years have also seen exciting advances in the chemical and physical characterization of polymer brushes, as well as an ever increasing set of computational and simulation tools that allow understanding and predictions of these surface-grafted polymer architectures. The aim of this contribution is to provide a comprehensive review that critically assesses recent advances in the field and highlights the opportunities and challenges for future work.

Preparation of Well-Defined Poly(styrene-co-acrylonitrile)/ZnO Hybrid Nanoparticles by an Efficient Ligand Exchange Strategy

Poly(styrene-co-acrylonitrile) (PSAN)-capped ZnO nanoparticles (NPs) were synthesized by a "ligand exchange" method. First, octylamine (OA)-capped ZnO NPs were prepared by reaction of OA and zinc 2-ethylhexanoate (Zn(EH)₂). Then PSAN polymer ligands were synthesized by activators regenerated by electron transfer (ARGET) atom transfer radical polymerization (ATRP) and were efficiently exchanged with OA ligands on the ZnO particle surface benefiting from the relatively low boiling point of OA (175 °C). The morphology, content of ZnO, and grafting density of the nanocomposite were well controlled by altering the ratio between OA and polymer ligands as well as the molecular weight of PSAN-NH₂ used in the exchange reaction. The resulting ZnO/polymer nanocomposites were stable in THF with narrow size distributions and varying grafting densities from 0.9 to 2.5 nm^-2. With excess amount of polymer ligands, individual dispersed ZnO NPs were observed. However, with a limited amount of ligands, NPs clusters were formed, as confirmed by TEM and DLS.

Enthalpy-Driven Stabilization of Dispersions of Polymer-Grafted Nanoparticles in High-Molecular-Weight Polymer Melts

Phase stability of polymer nanocomposites (PNCs) composed of polymer-grafted SiO₂ nanoparticles (NPs) blended with high-molar-mass host polymer chains is investigated. We focus on blends in which the particle-grafted polymer, polyethylene glycol (PEG), and the host-atactic poly(methylmethacrylate) (PMMA) or PMMA/oligo-PEG blends-exhibit favorable enthalpic interactions. Small-angle X-ray scattering measurements are used to evaluate the phase stability of the blends and to report on the structure of the materials at intermediate and long length scales. By exploring SiO₂-PEG/PMMA and SiO₂-PEG/PMMA-PEG systems covering a wide range of molecular weights (M_w) of PMMA (1.1 kDa ≤ M_w,PMMA ≤ 1.1 × 10³ kDa) and tethered PEG (0.5 kDa ≤ M_w, PEG ≤ 2 kDa), we are able to develop a comprehensive stability map for PNCs based on hairy NPs. At low M_w,PEG, the phase behavior is dominated by entropic effects and the negative Flory-Huggins χ parameter between PEG and PMMA plays no role in phase stability. For higher M_w,PEO and intermediate M_w,PMMA, a crossover from entropy- to enthalpy-dominated behavior is observed, which leads to the phase stability in PNCs well beyond the conventional limits reported for SiO₂-PEG/PEG mixtures. This enhanced mixing ceases above a critical M_w,PMMA, where it is found that PMMA chains wet a sufficiently large number of SiO₂-PEG particles to bridge and thereby destabilize the composites.

Confined Pattern-Directed Assembly of Polymer-Grafted Nanoparticles in a Phase Separating Blend with a Homopolymer Matrix

The controlled organization of nanoparticle (NP) constituents into superstructures of well-defined shape, composition and connectivity represents a continuing challenge in the development of novel hybrid materials for many technological applications. We show that the phase separation of polymer-tethered nanoparticles immersed in a chemically different polymer matrix provides an effective and scalable method for fabricating defined submicron-sized amorphous NP domains in melt polymer thin films. We investigate this phenomenon with a view towards understanding and controlling the phase separation process through directed nanoparticle assembly. In particular, we consider isothermally annealed thin films of polystyrene-grafted gold nanoparticles (AuPS) dispersed in a poly(methyl methacrylate) (PMMA) matrix. Classic binary polymer blend phase separation related morphology transitions, from discrete AuPS domains to bicontinuous to inverse domain structure with increasing nanoparticle composition is observed, yet the kinetics of the AuPS/PMMA polymer blends system exhibit unique features compared to the parent PS/PMMA homopolymer blend. We further illustrate how to pattern-align the phase-separated AuPS nanoparticle domain shape, size and location through the imposition of a simple and novel external symmetry-breaking perturbation via soft-lithography. Specifically, submicron-sized topographically patterned elastomer confinement is introduced to direct the nanoparticles into kinetically controlled long-range ordered domains, having a dense yet well-dispersed distribution of non-crystallizing nanoparticles. The simplicity, versatility and roll-to-roll adaptability of this novel method for controlled nanoparticle assembly should make it useful in creating desirable patterned nanoparticle domains for a variety of functional materials and applications.

Processing fragile matter: effect of polymer graft modification on the mechanical properties and processibility of (nano-) particulate solids

The effect of polymer modification on the deformation characteristics and processibility of particle assembly structures is analyzed as a function of particle size and degree of polymerization of surface-tethered chains. A pronounced increase of the fracture toughness (by approximately one order of magnitude) is observed as the degree of polymerization exceeds a threshold value that increases with particle size. The threshold value is interpreted as being related to the transition of tethered chains from stretched-to-relaxed conformation (and the associated entanglement of tethered chains) and agrees with predictions from scaling theory. The increase in toughness is reduced with increasing particle size - this effect is rationalized as a consequence of the decrease of entanglement density with increasing dimension of interstitial (void) space in particle array structures. The increased fracture toughness of particle brush materials (with sufficient degree of polymerization of tethered chains) enables the fabrication of ordered colloidal films and even complex 3D shapes by scalable polymer processing techniques, such as spin coating and micromolding. The results, therefore, suggest new opportunities for the processing of colloidal material systems that could find application in the economical fabrication of functional components or systems compromised of colloidal materials.

Grafting PMMA Brushes from α-Alumina Nanoparticles via SI-ATRP

Alumina nanoparticles are widely used as nanofillers for polymer nanocomposites. Among several different polymorphs of alumina, α-alumina has the most desirable combination of physical properties. Hence, the attachment of polymer chains to α-alumina to enhance compatibility in polymeric matrixes is an important goal. However, the chemical inertness and low concentration of surface hydroxyl groups have rendered polymer modification of α-alumina a long-standing challenge. Herein, we report that activation of α-alumina in concentrated or molten NaOH as well as in molten K2S2O7 increased polymer graft density up to 50%, thereby facilitating the synthesis of α-alumina brush particles with uniform grafting density of 0.05 nm(-2) that are readily miscible or dispersible in organic solvents or in chemically compatible polymeric hosts.

Tailoring structure formation and mechanical properties of particle brush solids via homopolymer addition

Recent progress in the area of surface-initiated controlled radical polymerization (SI-CRP) has enabled the synthesis of polymer-grafted colloids with precise control over the architecture of grafted chains. The resulting ‘particle brush materials’ are of interest both from a fundamental as well as applied perspective because structural frustrations (associated with the tethering of chains to a curved surface) imply a sensitive dependence of the interactions between brush particles on the architecture of surface-tethered chains that offers new opportunities to design hybrid materials with novel functionalities. An important prerequisite for establishing structure–property relations in particle brush materials is to understand the role of homopolymer impurities that form, for example, by thermal self-initiation. This contribution presents a detailed discussion of the role of homopolymer additives on the structure and mechanical properties of particle brush materials. The results suggest that the dissolution of homopolymer fillers follows a two-step mechanism comprised of the initial segregation of homopolymer to the interstitial regions within the array and the subsequent swelling of the particle brush (depending on the respective degree of polymerization of brush and linear chains). Addition of even small amounts of homopolymer is found to significantly increase the fracture toughness of particle brush assembly structures. The increased resistance to failure could enable the synthesis of robust colloidal crystal type materials that can be processed into complex shapes using ‘classical’ polymer forming techniques such as molding or extrusion.

Novel Nanocomposites of Poly(lauryl methacrylate)-Grafted Al2O3 Nanoparticles in LDPE

Aluminum oxide nanoparticles (NPs) were surface-modified by poly(lauryl methacrylate) (PLMA) using surface-initiated atom-transfer radical polymerization (SI-ATRP) of lauryl methacrylate. Nanocomposites were obtained by mixing the grafted NPs in a low-density polyethylene (LDPE) matrix in different ratios. First, the NPs were silanized with different aminosilanes, (3-aminopropyl)triethoxysilane, and 3-aminopropyl(diethoxy)methylsilane (APDMS). Subsequently, α-BiB, an initiator for SI-ATRP, was attached to the amino groups, showing higher immobilization ratios for APDMS and confirming that fewer self-condensation reactions between silanes took place. In a third step SI-ATRP of LMA at different times was performed to render PLMA-grafted NPs (NP-PLMAs), showing good control of the polymerization. Reactions were conducted for 20 to 60 min, obtaining a range of molecular weights between 23 000 and 83 000 g/mol, as confirmed by size-exclusion chromoatography of the cleaved grafts. Nanocomposites of NP-PLMAs at low loadings in LDPE were prepared by extrusion. At low loadings, 0.5 wt % of inorganic content, the second yield point, storage, and loss moduli increased significantly, suggesting an improved interphase as an effect of the PLMA grafts. These observations were also confirmed by an increase in transparency of the nanocomposite films. At higher loadings, 1 wt % of inorganics, the increasing amount of PLMA gave rise to the formation of small aggregates, which may explain the loss of mechanical properties. Finally, dielectric measurements were performed, showing a decrease in tan δ values for LDPE-NP-PLMAs, as compared to the nanocomposites containing unmodified NP, thus indicating an improved interphase between the NPs and LDPE.

High-transparency polymer nanocomposites enabled by polymer-graft modification of particle fillers

The role of polymeric ligands on the optical transparency of polymer-matrix composites is analyzed by evaluating the effect of surface modification on the scattering cross-section of particle fillers in uniform particle dispersions. For the particular case of poly(styrene-r-acrylonitrile)-grafted silica particles embedded in poly(methyl methacrylate), it is shown that the tethering of polymeric chains with appropriate optical properties (such as to match the effective refractive index of the brush particle to the embedding matrix) facilitates the reduction of the particle scattering cross-section by several orders of magnitude as compared to pristine particle analogues. The conditions for minimizing the scattering cross-section of particle fillers by polymer-graft modification are established on the basis of effective medium as well as core-shell Mie theory and validated against experimental data on uniform liquid and solid particle dispersions. Effective medium theory is demonstrated to provide robust estimates of the "optimum polymer-graft composition" to minimize the scattering cross-section of particle fillers even in the limit of large particle dimensions (comparable to the wavelength of light). The application of polymer-graft modification to the design of large (500 nm diameter) silica particle composites with reduced scattering cross-section is demonstrated.

Macromolecular engineering by atom transfer radical polymerization

This Perspective presents recent advances in macromolecular engineering enabled by ATRP. They include the fundamental mechanistic and synthetic features of ATRP with emphasis on various catalytic/initiation systems that use parts-per-million concentrations of Cu catalysts and can be run in environmentally friendly media, e.g., water. The roles of the major components of ATRP--monomers, initiators, catalysts, and various additives--are explained, and their reactivity and structure are correlated. The effects of media and external stimuli on polymerization rates and control are presented. Some examples of precisely controlled elements of macromolecular architecture, such as chain uniformity, composition, topology, and functionality, are discussed. Syntheses of polymers with complex architecture, various hybrids, and bioconjugates are illustrated. Examples of current and forthcoming applications of ATRP are covered. Future challenges and perspectives for macromolecular engineering by ATRP are discussed.

25th anniversary article: polymer-particle composites: phase stability and applications in electrochemical energy storage

Polymer-particle composites are used in virtually every field of technology. When the particles approach nanometer dimensions, large interfacial regions are created. In favorable situations, the spatial distribution of these interfaces can be controlled to create new hybrid materials with physical and transport properties inaccessible in their constituents or poorly prepared mixtures. This review surveys progress in the last decade in understanding phase behavior, structure, and properties of nanoparticle-polymer composites. The review takes a decidedly polymers perspective and explores how physical and chemical approaches may be employed to create hybrids with controlled distribution of particles. Applications are studied in two contexts of contemporary interest: battery electrolytes and electrodes. In the former, the role of dispersed and aggregated particles on ion-transport is considered. In the latter, the polymer is employed in such small quantities that it has been historically given titles such as binder and carbon precursor that underscore its perceived secondary role. Considering the myriad functions the binder plays in an electrode, it is surprising that highly filled composites have not received more attention. Opportunities in this and related areas are highlighted where recent advances in synthesis and polymer science are inspiring new approaches, and where newcomers to the field could make important contributions.