In this work the potential of graphene-like particles for mechanical reinforcement is investigated. Different polymer processing methods are studied from traditional ones to more advanced techniques. The potential of graphene as a reinforcement for polymer composites is addressed as a result of polymer modifications and the morphology of the graphene like particles. First, a composites of polycarbonate (PC) and graphite nanoplatelets (GNP) are produced by a traditional melt-mixing method. The GNP composites present a low mechanical reinforcing efficiency which is believed to be due to a poor dispersion of the GNP and a weak interaction between the GNP and the matrix. Secondly, solution cast composites of polyvinyl alcohol (PVA) with very low loadings of graphene oxide (GO) are produced. The polymer morphology undergoes some modifications after the addition of GO. A strong increase of the Tg is observed after the addition of GO which is the result of a reduction in polymer mobility, while a dramatic increase of the mechanical properties is seen as well. Uni-axial drawing is applied in order to align the particles. No polymer modifications are observed between the drawn PVA and the drawn nanocomposites due to the strong alignment of the polymer chains during the drawing. Mechanical reinforcement is observed after addition of the GO showing real reinforcement. Finally, a more advanced processing method is investigated using spraying. The condition of spraying a layer of polymer and GO is studied. Finally a hierarchical composite of PVA - GO is produced by this spraying method. 150 bi-layers are deposited to create a film with improved mechanical properties at a loading of 5.4 wt.% GO. The Young’s modulus and strength of these films doubled or nearly doubled which is believed to be due to the high level of structural organization of the layered nanocomposite incorporating the 2D GO nanofiller, together with hydrogen bonding between the PVA and the GO sheets.

Graphene Nanoplatelets (GNP) was incorporated into polyamide 6 (PA6) matrix by melt compounding method and the enhancements in the properties of the nanocomposites were studied. Response Surface Methodology (RSM) was employed to assist in the study of processing conditions in melt compounding. RSM analysis revealed that the GNP concentrations to be the most significant term to affect the tensile modulus and crystallinity followed by the screw speed whereas the residence time was found to be non-significant. GNP with 5 Î1⁄4m (G5) and 25 Î1⁄4m (G25) were used in the GNP aspect ratio study. The average flake size of G5 and G25 to was measured to be 5.07 Î1⁄4m and 22.0 Î1⁄4m, respectively with the G5 distributed narrowly whereas the G25 exhibit broad distribution. TGA analysis shown that HT25 is more thermally stable compared to G25 due to some remnants lost during thermal treatment and this was confirmed by EDX and CHNS analysis. XRD profiles of the PA6-G-NC illustrate typical peaks of PA6 crystals phase as well as pure graphite characteristic peak. PA6-G25-NC observed to exhibit slightly higher peak intensity compared to PA6-G5-NC suggesting more formation of PA6 crystals. Similar improvement was observed on PA6-HT25-NC compared to PA6-G25-NC indicating more formation of PA6 crystals due improved dispersion of HT25. DSC on PA6-G25-NC showed higher cooling temperature and crystallinity compared to PA6-G5-NC due to larger surface area of the G25. Similarly, PA6-HT25 showed better improvement in crystallinity over PA6-G25-NC due to increase nucleation sites by the HT25. The thermal conductivity of PA6-G25-NC is slightly higher than the thermal conductivity of PA6-G5-NC but not significant considering the G25 is 5 times larger than G5. Instead, no significant difference was observed between PA6-HT25-NC and PA6-G25-NC. Addition of GNP increased the thermal stability of the PA6-G-NC systems under both nitrogen and air atmospheres regardless of the GNP aspect ratio. The viscoelastic properties showed insignificant difference between PA6-G5-NC and PA6-G25-NC. The inefficient improvement by G25 might be due to agglomeration formed during processing. The storage modulus and tan Î ́ of PA6-HT25-NC decreased but the Tg significantly improved compared to PA6-G25-NC. This was assumed to be because of improved dispersion of HT25 but reduced interfacial interaction after the heat treatment. The shear storage modulus, G’ and complex viscosity, |η*| were observed to increase with increasing GNP content with more pronounced improvement seen on PA6-G25-NC compared to PA6-G5-NC. However, no network percolation threshold was observed until 20 wt.% of GNP. The poor interfacial interaction of HT25 resulted in lower G’ and |η*| compared to G25. Tensile test results showed typical improvement with PA6-G25-NC having higher tensile modulus compared to PA6-G5-NC. Further enhancement was obtained with PA6-HT25-NC suggesting improved dispersion and volume of constrained chains mobility despite the poor surface interaction. Comparison with Halphin-Tsai modulus revealed that the effective modulus to be 150 GPa for G5 and 200 GPa for G25. The water uptake measurement results showed that GNP reduced the water uptake percentage and diffusion coefficient especially with G25. The test conducted on saturated PA6-G-NC results in improved thermal conductivity due to the high thermal conductivity of water but the viscoelastic and tensile properties severely reduced due to plasticisation effect.

This thesis focuses on improved processing methods for enhanced mechanical properties in polymer nanocomposites, and controlled drug release in polymer based delivery systems. Supercritical carbon dioxide assisted mixing was successfully used in preparation of polypropylene/sepiolite and polypropylene/multiwall carbon nanotube nanocomposites. Relatively homogeneous dispersed and well separated nanofillers were obtained throughout the PP matrix. A better preservation of nanofiller lengths was observed in the scCO 2 assisted mixing. Mechanical property studies showed a marked increase in Young's modulus and tensile strength with the addition of nanofillers. More interestingly, techniques usually designed to achieve high quality PP nanocomposites, such as the use of masterbatches, maleic anhydride grafted polypropylene compatibilizers or polymer coated MWNTs are not needed to achieve equivalent mechanical properties with scCO2 assisted mixing. ScCO2 was also used as a foaming technique to modify the traditional cured poly(ethyl methacrylate/tetrahydrofurfuryl methacrylate) system for a controlled release of chlorhexidine. Highly porous structures were produced and chlorhexidine released from scCO2 foamed samples was more than 3 times higher than traditionally cured samples. By altering the processing conditions, such as CO2 saturation time and depressurization time the CX release rate was altered. Finally, the electrospinning method was combined with the layering encapsulation technique in order to enable the incorporation of water-soluble drugs in poly(lactic-co-glycolic acid) fibres for biomedical applications. Water-soluble drug, Rhodamine 6G or protein bovine serum albumin, loaded calcium carbonate microparticles were successfully incorporated in PLGA fibres and a bead and string structured composite fibres.

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For the commercial success of polymer - multiwalled carbon nanotube (MWNT) composites the production of these materials on industrial scale by melt processing is of significant importance. The complete dispersion of primary MWNT agglomerates in a polymer melt is difficult to achieve, making it an important and challenging technological problem. Hence, it is necessary to understand the process of MWNT agglomerate dispersion in a polymer melt. Based on an intensive literature research on mechanisms and influencing factors on dispersion of other agglomerated nanostructured fillers (e.g. carbon black), the main dispersion steps were evaluated and investigated concerning the agglomerated MWNT.Consequently, systematic investigations were performed to study the effect of the melt infiltration on MWNT agglomerate dispersion and to analyse the corresponding main dispersion mechanisms, namely rupture and erosion. The states of MWNT agglomerate dispersion were assessed by quantifying the agglomerate area ratio and particle size distribution using image analysis of optical transmission micrographs. Additionally, the composite’s electrical resistivity was determined. In the prevailing study, polycarbonates (PC) varying in molecular weight were used to produce composites containing 1 wt% MWNT (Baytubes C150HP) as model systems and a discontinuous microcompounder was applied as melt mixing device. The agglomerate structure of the used MWNT material made them especially suitable for the reported investigations. The step of melt infiltration into the primary nanotube agglomerates plays a crucial role for their dispersion in the PC melt. During melt mixing when low shear rates were applied, better state of MWNT dispersion was obtained in high viscosity matrices because applied shear stresses were high. On the contrary, if high shear rates were applied, similar states of MWNT dispersion were obtained in low and high viscosity matrices although significantly lower shear stresses were applied in the low viscosity matrix as compared to the high viscosity matrix. The results indicate that if the applied shear stress values are compared, with increasing matrix viscosity the agglomerate dispersion gets worsen. This is attributed to the fact that low viscosity matrices can infiltrate relatively faster than high viscosity matrices into the agglomerate making them weaker and reducing the agglomerate strength. Thus, at sufficient shear rates MWNT agglomerates disperse relatively faster in low viscosity matrix. This illustrates a balance between the counteracting effects of viscosity on agglomerate infiltration and agglomerate dispersion. Additionally, the effect of matrix molecular weight on the size of un-dispersed MWNT agglomerates was investigated. Under similar conditions of applied shear stress, the composites based on low molecular weight matrix showed smaller sized un-dispersed primary agglomerates as compared to composites with higher molecular weight matrices. This again highlights the role of matrix infiltration as the first step of dispersion. Following the step of melt infiltration, agglomerate size gets reduced due to the dispersion mechanisms. To analyse the corresponding contributions of different dispersion mechanisms (rupture and erosion), the kinetics of MWNT agglomerate dispersion was investigated. If high mixing speeds are employed dispersion is quite fast and needs less time as compared to low mixing speed. A model is proposed to estimate the fractions of rupture and erosion mechanisms during agglomerate dispersion based on the kinetic study in the discontinuous mixer. Under the employed experimental conditions, at high mixing speeds, the dispersion was found to be governed by rupture dominant mechanism, whereas at low mixing speeds the dispersion was controlled by both mechanisms. As far as electrical resistivity is concerned, for a given content of MWNT as the state of dispersion improves, the resistivity values decrease significantly but only up to a plateau value. The composites produced using low viscosity matrices have lower resistivity values as compared to high viscosity matrices. Additionally, composites were prepared using additives, whereas the additives were found to be useful for improving filler dispersion and electrical conductivity.