Polymer nanocomposite technology has had significant impact on material design. With the environmental advantages of photopolymerization, a research has recently focused on producing nanocomposites utilizing inexpensive clay particles based on in situ photopolymerization. In this research, novel polymerizable organoclays and thiol-ene photopolymerization have been utilized to develop advanced photopolymer clay nanocomposites and to overcome several limitations in conventional free radical photopolymers. To this end, factors important in nanocomposite processes such as monomer composition, clay dispersion, and photopolymerization behavior in combination with the evolution of ultimate nanocomposite properties have been investigated. For monomer-organoclay compositions, higher chemical compatibility of components induces enhanced clay exfoliation, resulting in photopolymerization rate increases due to an amplified clay template effect. Additionally, by affecting the stoichiometric ratio between thiol and acrylate double bond in the clay gallery, thiolated organoclays enhance thiol-ene copolymerization with increased final thiol conversion while acrylated organoclays encourage acrylate homopolymerization. In accordance with the reaction behavior, incorporation of thiolated organoclays makes polymer chains more flexible with decreased glass transition temperature due to higher formation of thio-ether linkages while adding acrylated organoclays significantly increases the modulus. Photopolymer nanocomposites also help overcome two major drawbacks in conventional free radical photopolymerization, namely severe polymerization shrinkage and oxygen inhibition during polymerization. With addition of a low level of thiol monomers, the oxygen inhibition in various acrylate systems can be overcome by addition of only 5wt% thiolated organoclay. The same amount of polymerizable organoclay also induces up to 90% decreases in the shrinkage stress for acrylate or thiol-acrylate systems. However, nonreactive clays do not reduce the stress substantially and even decreases the polymerization rate in air. Additionally, the clay morphology and polymerization behavior are closely related with evolution of ultimate nanocomposite performance. Use of polymerizable organoclay significantly improves overall toughness of nanocomposites by increasing either modulus or elongation at break based on the type of polymerizable organoclay, which demonstrates the promise of this technology as a modulation and/or optimization tool for nanocomposite properties.

ABSTRACT PRODUCTION AND CHARACTERIZATION OF RESOL TYPE PHENOLIC RESIN / LAYERED SILICATE NANOCOMPOSITES TaSan, Cemal Cem M.S., Department of Metallurgical and Materials Engineering Supervisor: Assoc.Prof. Cevdet Kaynak April 2005 133 Pages Polymer / layered silicate (P/LS) nanocomposites belong to one of the most promising group of materials of the past few decades and most probably for the near future. Combining two of the most widely studied topics of material science: composite materials and nanotechnology / P/LS research have drawn great attention starting with the pioneering works of Toyota Research Group in 1980&rsquo / s. The research is now being carried out world wide / since the excellent properties of these new materials, which is achieved by using very low amounts of a cheap reinforcement material (clay), increases the interest on these materials everyday after. In this present study, the object was to investigate the production parameters of phenol formaldehyde based layered silicate nanocomposites. For this purpose, 14 different specimen groups were produced / using two different resol type phenolic resins (PF76 and PF76TD) as the matrix / and 9 different montmorillonite clays (Rheospan, Resadiye, Cloisite Na+, 10A, 15A, 20A, 25A, 30B, 94A) as the reinforcement phase. Initially the curing schedules for the available resins were experimentally determined. Then, a short and effective mixing procedure for the thermosetting resin and the montmorillonite clay was developed. The effects of several processing parameters / such as clay type, clay source, clay content, clay modification, resin type, resin cure type, cure cycle and mixing cycle were determined by X-ray Diffraction, Scanning Electron Microscopy and Mechanical Tests. Then, Transmission Electron Microscopy was used to investigate the level of intercalation and/or exfoliation of the layered silicates. Finally, Differential Scanning Calorimetry was also carried out to analyse thermal properties of the specimens. It was concluded that, a partially intercalated and/or exfoliated structure could be obtained in resol type phenolic resin based systems at very low clay contents (such as 0,5%) leading to remarkable increases in mechanical properties (e.g. 66% increase in fracture toughness).

The potential use of Resadiye/Tokat bentonite as a reinforcement in polypropylene (PP) and linear low density polyethylene (LLDPE) polymer matrix nanocomposites filler was investigated. At first, organoclays (OC) were prepared by cation exchange reaction (CER) between the raw bentonite (RB) and three quaternary ammonium salts with long alkyl tails (QA): hexadecyl trimethyl ammonium bromide [HMA] [Br], tetrabutyl ammonium tetrafluoroborate [TBA] [BF4], tetrakisdecyl ammonium bromide [TKA] [Br] and one quaternary phosphonium (QP) salt: tetrabutyl phosphonium tetrafluroborate [TBP] [BF4]. Characterization of resulting materials by XRD, TGA, FTIR and chemical analysis confirmed the formation of organoclays. Ternary composites of PP/organoclay/ maleic anhydride grafted polypropylene (MAPP) were prepared with two different grades of PPs in a co-rotating twin screw extruder. Composites prepared with these organoclays and PPs showed microcomposite formation. In the second part of the study, raw bentonite was purified by sedimentation, and characterization of purified bentonite (PB) by XRD, cation exchange capacity (CEC) measurement and chemical analysis (ICP) confirmed the success of purification method. PB was then modified with two QA`s: dimethyl dioctadecylammonium chloride [DMDA] [Cl], tetrakis decylammonium bromide [STKA] [Br] and one QP: tributyl hexadecyl phosphonium bromide [TBHP] [Br]. Organoclays from PB were used with the PP with lower viscosity, and ternary nanocomposites (PP/Organoclay2/MAPP5) were prepared in the extruder followed by batch mixing in an intensive batch mixer. Use of DMDA and TBHP OCs resulted in nanocomposite formation, while STKA resulted in microcomposite formation as observed by XRD and TEM. Young`s modulus and yield stress of the samples were enhanced through nanocomposite formation. In the last part of the study, ternary composites of LLDPE/Organoclay/ compatibilizer, a random terpolymer of ethylene, butyl acrylate and maleic anhydride (E-BA-MAH, Lotader&reg / 3210), were prepared by melt compounding in the batch mixer at two different clay concentrations (2 and 5 wt %) and fixed compatibilizer/organoclay ratio (&alpha / =2.5). A commercial organoclay, I34, was also used in LLDPE based nanocomposites to make a comparison. XRD and TEM analyses of the compounds prepared by DMDA and TBHP showed mixed nanocomposite morphologies consisting of partially intercalated and exfoliated layers. Young`s modulus and tensile strength of nanocomposites prepared with DMDA and TBHP showed generally higher values compared to those of neat LLDPE, while results were the highest in the composites prepared with commercial organoclay I34. Parallel disk rheometry was used as a supplementary technique to XRD, TEM and mechanical characterizations, and it was shown to be a sensitive tool in assessing the degree of dispersion of clay layers in the polymer matrix.