Reinforcement and Polymer Mobility in Silica–Latex Nanocomposites with Controlled Aggregation

Tunable distribution of silica nanoparticles in water-borne coatings via strawberry supracolloidal dispersions

HYPOTHESIS

Water-borne coatings are rapidly expanding as sustainable alternatives to organic solvent-borne systems. Inorganic colloids are often added to aqueous polymer dispersions to enhance the performance of water-borne coatings. However, these bimodal dispersions have many interfaces which can result in unstable colloids and undesirable phase separation. The covalent bonding between individual colloids, on a polymer-inorganic core-corona supracolloidal assembly, could reduce or suppress instability and phase separation during drying of coatings, advancing its mechanical and optical properties.

METHODS

Aqueous polymer-silica supracolloids with a core-corona strawberry configuration were used to precisely control the silica nanoparticles distribution within the coating. The interaction between polymer and silica particles was fine-tuned to obtain covalently bound or physically adsorbed supracolloids. Coatings were prepared by drying the supracolloidal dispersions at room temperature, and their morphology and mechanical properties were interconnected.

FINDINGS

Covalently bound supracolloids provided transparent coatings with a homogeneous 3D percolating silica nanonetwork. Supracolloids having physical adsorption only, resulted in coatings with a stratified silica layer at interfaces. The well-arranged silica nanonetworks strongly improve the storage moduli and water resistance of the coatings. These supracolloidal dispersions offer a new paradigm for preparing water-borne coatings with enhanced mechanical properties and other functionalities, like structural color.

Competitive Adsorption between a Polymer and Solvents onto Silica

In polymer nanocomposites, particle-polymer interactions play a key role both in the processing and in the final properties of the obtained materials. Specifically, for silica, because of the surface polarity, surface modification is commonly used to improve the compatibility with apolar polymer matrices in order to prevent agglomeration. In this work, a new way to investigate the polymer-silica affinity and determine dispersibility parameters (HDP) of silica particles in the 3D Hansen space using a solvent approach is proposed. These parameters are estimated from the assessment of the stability of suspensions in a set of organic solvents. Based on the respective locations of the solvent, polymer, and silica representative points in the 3D Hansen space, the adsorption of a given polymer in solution in a given solvent can be predicted. This is shown with the industrial precipitated silica Zeosil 1165MP in combination with polystyrene and polybutadiene. It is shown that silanization of the silica particles decreases the adsorption of polystyrene, even though because of this surface treatment, silica comes closer to polystyrene in the Hansen space. This counter-intuitive effect is rationalized based on the consideration of an adsorption parameter χ_S computed from the relative locations of the solvent, polymer, and particles in the 3D Hansen space. Basically, this parameter is related to the respective distances of the solvent and polymer representative points to that of the particle in the Hansen space.

In Situ Modification of Polyisoprene by Organo-Nanoclay during Emulsion Polymerization for Reinforcing Natural Rubber Thin Films

Nanoclay-modified polyisoprene latexes were prepared and then used as a reinforcing component in natural rubber (NR) thin films. Starve-fed emulsion (SFE) polymerization gives a higher conversion than the batch emulsion (BE), while the gel and coagulation contents from both systems are comparable. This is attributed to the SFE that provides a smaller average polymer particle size which in turn results in a greater polymerization locus, promoting the reaction rate. The addition of organo-nanoclay during synthesizing polyisoprene significantly lessens the polymerization efficiency because the nanoclay has a potential to suppress nucleation process of the reaction. It also intervenes the stabilizing efficiency of the surfactant—SDS or sodium dodecyl sulfate, giving enlarged average sizes of the polymer particles suspended in the latexes. TEM images show that nanoclay particles are attached on and/or inserted in the polymer particles. XRD and thermal (differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA)) analyses were employed to assess the d-spacing of nanoclay structure in NR nanocomposite films, respectively. Based on the overall results, 5 wt% of nanoclay relative to the monomer content utilized to alter the polyisoprene during emulsion polymerization is an optimum amount since the silicate plates of nanoclay in the composite exhibit the largest d-spacing which maximizes the extent of immobilized polymer constituent, giving the highest mechanical properties to the films. The excessive amounts of nanoclay used, i.e., 7 and 10 wt% relative to the monomer content, reduce the reinforcing power because of the re-agglomeration effect.

Nanoparticle self-assembly: from interactions in suspension to polymer nanocomposites

Recent experimental results using in particular small-angle scattering to characterize the self-assembly of mainly hard spherical nanoparticles into higher ordered structures ranging from fractal aggregates to ordered assemblies are reviewed. The crucial control of interparticle interactions is discussed, from chemical surface-modification, or the action of additives like depletion agents, to the generation of directional patches and the use of external fields. It is shown how the properties of interparticle interactions have been used to allow inducing and possibly controlling aggregation, opening the road to the generation of colloidal molecules or potentially metamaterials. In the last part, studies of the microstructure of polymer nanocomposites as an application of volume-spanning and stress-carrying aggregates are discussed.

Aggregate Formation of Surface-Modified Nanoparticles in Solvents and Polymer Nanocomposites

A new method based on the combination of small-angle scattering, reverse Monte Carlo simulations, and an aggregate recognition algorithm is proposed to characterize the structure of nanoparticle suspensions in solvents and polymer nanocomposites, allowing detailed studies of the impact of different nanoparticle surface modifications. Experimental small-angle scattering is reproduced using simulated annealing of configurations of polydisperse particles in a simulation box compatible with the lowest experimental q-vector. Then, properties of interest like aggregation states are extracted from these configurations and averaged. This approach has been applied to silane surface-modified silica nanoparticles with different grafting groups, in solvents and after casting into polymer matrices. It is shown that the chemistry of the silane function, in particular mono- or trifunctionality possibly related to patch formation, affects the dispersion state in a given medium, in spite of an unchanged alkyl-chain length. Our approach may be applied to study any dispersion or aggregation state of nanoparticles. Concerning nanocomposites, the method has potential impact on the design of new formulations allowing controlled tuning of nanoparticle dispersion.

Introduction to soft matter and neutron scattering

As an opening lecture to the French-Swedish neutron scattering school held in Uppsala (6th to 9th of December 2016), the basic concepts of both soft matter science and neutron scattering are introduced. Typical soft matter systems like self-assembled surfactants in water, microemulsions, (co-)polymers, and colloids are presented. It will be shown that widely different systems have a common underlying physics dominated by the thermal energy, with astonishing consequences on their statistical thermodynamics, and ultimately rheological properties – namely softness. In the second part, the fundamentals of neutron scattering techniques and in particular small-angle neutron scattering as a powerful method to characterize soft matter systems will be outlined.

Determination of the local density of polydisperse nanoparticle assemblies

Quantitative characterization of the average structure of dense nanoparticle assemblies and aggregates is a common problem in nanoscience. Small-angle scattering is a suitable technique, but it is usually limited to not too big assemblies due to the limited experimental range, low concentrations to avoid interactions, and monodispersity to keep calculations tractable. In the present paper, a straightforward analysis of the generally available scattered intensity - even for large assemblies, at high concentrations - is detailed, providing information on the local volume fraction of polydisperse particles with hard sphere interactions. It is based on the identical local structure of infinite homogeneous nanoparticle assemblies and their subsets forming finite-sized clusters. This approach is extended to polydispersity, using Monte-Carlo simulations of hard and moderately sticky hard spheres. As a result, a simple relationship between the observed structure factor minimum - termed the correlation hole - and the average local volume fraction κ on the scale of neighboring particles is proposed and validated through independent aggregate simulations. This relationship shall be useful as an efficient tool for the structural analysis of arbitrarily aggregated colloidal systems.

Interplay between polymer chain conformation and nanoparticle assembly in model industrial silica/rubber nanocomposites

The question of the influence of nanoparticles (NPs) on chain dimensions in polymer nanocomposites (PNCs) has been treated mainly through the fundamental way using theoretical or simulation tools and experiments on well-defined model PNCs. Here we present the first experimental study on the influence of NPs on the polymer chain conformation for PNCs designed to be as close as possible to industrial systems employed in the tire industry. PNCs are silica nanoparticles dispersed in a styrene-butadiene-rubber (SBR) matrix whose NP dispersion can be managed by NP loading with interfacial coatings or coupling additives usually employed in the manufacturing mixing process. We associated specific chain (d) labeling, and the so-called zero average contrast (ZAC) method, with SANS, in situ SANS and SAXS/TEM experiments to extract the polymer chain scattering signal at rest for non-cross linked and under stretching for cross-linked PNCs. NP loading, individual clusters or connected networks, as well as the influence of the type, the quantity of interfacial agent and the influence of the elongation rate have been evaluated on the chain conformation and on its related deformation. We clearly distinguish the situations where the silica is perfectly matched from those with unperfected matching by direct comparison of SANS and SAXS structure factors. Whatever the silica matching situation, the additive type and quantity and the filler content, there is no significant change in the polymer dimension for NP loading up to 15% v/v within a range of 5%. One can see an extra scattering contribution at low Q, as often encountered, enhanced for non-perfect silica matching but also visible for perfect filler matching. This contribution can be qualitatively attributed to specific h or d chain adsorption on the NP surface inside the NP cluster that modifies the average scattering neutron contrast of the silica cluster. Under elongation, NPs act as additional cross-linking junctions preventing chain relaxation and giving a deformation of the chain with the NP closer to a theoretical phantom network prediction than a pure matrix.

Revealing nanocomposite filler structures by swelling and small-angle X-ray scattering

Polymer nanocomposites are used widely, mainly for the industrial application of car tyres. The rheological behavior of such nanocomposites depends in a crucial way on the dispersion of the hard filler particles – typically silica nanoparticles embedded in a soft polymer matrix. It is thus important to assess the filler structure, which may be quite difficult for aggregates of nanoparticles of high polydispersity, and with strong interactions at high loading. This has been achieved recently using a coupled TEM/SAXS structural model describing the filler microstructure of simplified industrial nanocomposites with grafted or ungrafted silica of high structural disorder. Here, we present an original method capable of reducing inter-aggregate interactions by swelling of nanocomposites, diluting the filler to low-volume fractions. Note that this is impossible to reach by solid mixing due to the large differences in viscoelasticity between the composite and the pure polymer. By combining matrix crosslinking, swelling in a good monomer solvent, and post-polymerization of these monomers, it is shown that it is possible to separate the filler into small aggregates. The latter have then been characterized by electron microscopy and small-angle X-ray scattering, confirming the conclusions of the above mentioned TEM-SAXS structural model applied directly to the highly loaded cases.

Surface modification of alumina-coated silica nanoparticles in aqueous sols with phosphonic acids and impact on nanoparticle interactions

It is often necessary to tailor nanoparticle (NP) interactions and their compatibility with a polymer matrix by grafting organic groups, but the commonly used silanization route offers little versatility, particularly in water. Herein, alumina-coated silica NPs in aqueous sols have been modified for the first time with low molecular-weight phosphonic acids (PAs) bearing organic groups of various hydrophobicities and charges: propyl, pentyl and octyl PAs, and two PAs bearing hydrophilic groups, either a neutral diethylene glycol (DEPA) or a potentially charged carboxylic acid (CAPA) group. The interactions and aggregation in the sols have been investigated using zeta potential measurements, dynamic light scattering, transmission electron microscopy, and small-angle scattering methods. The surface modification has been studied using FTIR and (31)P MAS NMR spectroscopies. Both high grafting density ρ and high hydrophobicity of the groups on the PAs induced aggregation, whereas suspensions of NPs grafted by DEPA remained stable up to the highest ρ. Unexpectedly, CAPA-modified NPs showed aggregation even at low ρ, suggesting that the carboxylic end group was also grafted to the surface. Surface modification of aqueous sols with PAs allows thus for the grafting of a higher density and a wider variety of organic groups than organosilanes, offering an increased control of the interactions between NPs, which is of interest for designing waterborne nanocomposites.

Poly(vinyl alcohol)/cellulose nanofibril hybrid aerogels with an aligned microtubular porous structure and their composites with polydimethylsiloxane

Superhydrophobic poly(vinyl alcohol) (PVA)/cellulose nanofibril (CNF) aerogels with a unidirectionally aligned microtubular porous structure were prepared using a unidirectional freeze-drying process, followed by the thermal chemical vapor deposition of methyltrichlorosilane. The silanized aerogels were characterized using various techniques including scanning electron microscopy (SEM), Fourier transform infrared spectroscopy, and contact angle measurements. The structure of the aerogels fully filled with polydimethylsiloxane (PDMS) was confirmed by SEM and optical microscopy. The mechanical properties of the resulting PDMS/aerogel composites were examined using both compressive and tensile tests. The compressive and tensile Young's moduli of the fully filled PDMS/aerogel composites were more than 2-fold and 15-fold higher than those of pure PDMS. This study provides a novel alternative approach for preparing high performance polymer nanocomposites with a bicontinuous structure.

Mechanism of aggregate formation in simplified industrial silica styrene-butadiene nanocomposites: effect of chain mass and grafting on rheology and structure

The formation of aggregates in simplified industrial styrene-butadiene nanocomposites with silica filler has been studied using a recent model based on a combination of electron microscopy, computer simulations, and small-angle X-ray scattering. The influence of the chain mass (40 to 280 kg mol(-1), PI < 1.1), which sets the linear rheology of the samples, was investigated for a low (9.5 vol%) and high (19 vol%) silica volume fraction. 50% of the chains bear a single graftable end-group, and it is shown that the (chain-mass dependent) grafting density is the structure-determining parameter. A model unifying all available data on this system is proposed and used to determine a critical aggregate grafting density. The latter is found to be closely related to the mushroom-to-brush transition of the grafted layer. To our best knowledge, this is the first comprehensive evidence for the control of the complex nanoparticle aggregate structure in nanocomposites of industrial relevance by the physical parameters of the grafted layer.

A novel non-aqueous sol-gel route for the in situ synthesis of high loaded silica-rubber nanocomposites

Silica-natural rubber nanocomposites were obtained through a novel non-aqueous in situ sol-gel synthesis, producing the amount of water necessary to induce the hydrolysis and condensation of a tetraethoxysilane precursor by esterification of formic acid with ethanol. The method allows the synthesis of low hydrophilic silica nanoparticles with ethoxy groups linked to the silica surface which enable the filler to be more dispersible in the hydrophobic rubber. Thus, high loaded silica composites (75 phr, parts per hundred rubber) were obtained without using any coupling agent. Transmission Electron Microscopy (TEM) showed that the silica nanoparticles are surrounded by rubber layers, which lower the direct interparticle contact in the filler-filler interaction. At the lowest silica loading (up to 30 phr) silica particles are isolated in rubber and only at a large amount of filler (>60 phr) the interparticle distances decrease and a continuous percolative network, connected by thin polymer films, forms throughout the matrix. The dynamic-mechanical properties confirm that the strong reinforcement of the rubber composites is related to the network formation at high loading. Both the improvement of the particle dispersion and the enhancement of the silica loading are peculiar to the non-aqueous synthesis approach, making the method potentially interesting for the production of high-loaded silica-polymer nanocomposites.

In situ determination of interfacial energies between heterogeneously nucleated CaCO3 and quartz substrates: thermodynamics of CO2 mineral trapping

The precipitation of carbonate minerals--mineral trapping--is considered one of the safest sequestration mechanisms ensuring long-term geologic storage of CO(2). However, little is known about the thermodynamic factors controlling the extent of heterogeneous nucleation at mineral surfaces exposed to the fluids in porous reservoirs. The goal of this study is to determine the thermodynamic factors controlling heterogeneous nucleation of carbonate minerals on pristine quartz (100) surfaces, which are assumed representative of sandstone reservoirs. To probe CaCO(3) nucleation on quartz (100) in solution and with nanoscale resolution, an in situ grazing incidence small-angle X-ray scattering technique has been utilized. With this method, a value of α' = 36 ± 5 mJ/m(2) for the effective interfacial free energy governing heterogeneous nucleation of CaCO(3) has been obtained by measuring nucleation rates at different solution supersaturations. This value is lower than the interfacial energy governing calcite homogeneous nucleation (α ≈ 120 mJ/m(2)), suggesting that heterogeneous nucleation of calcium carbonate is favored on quartz (100) at ambient pressure and temperature conditions, with nucleation barriers between 2.5% and 15% lower than those expected for homogeneous nucleation. These observations yield important quantitative parameters readily usable in reactive transport models of nucleation at the reservoir scale.