A novel fabrication method for poly(propylene)/clay nanocomposites by continuous processing

It is well known that poly(propylene)/clay (PP/clay) nanocomposite forms an exfoliated structure when mixed with maleic anhydride-functionalized polypropylene (MAPP). This can be easily achieved by melt processing, however, the use of functionalized chemicals like MAPP costs a lot preventing its commercial application. Recently, it was reported that the exfoliated structure of PP/clay nanocomposite could be obtained without using any compatibilizer such as MAPP when exposed to the electric field. They could regulate the degree of dispersion and exfoliation by controlling the amount of clay loading, the strength of electric field, the time exposed to the electric field, etc. However, this was accomplished by applying the electric field on a rheometer for a long time. It will be practically attractive if we produce PP/clay nanocomposites via continuous processing like extrusion. A new design concept is required for this purpose. In this study, we present a novel method to continuously produce PP/clay nanocomposites using the electric melt pipe equipped with a twin-screw extruder. Rheology, XRD, and SEM measurements confirm the formation of nanocomposites. Thermal- and dynamic-mechanical analysis also shows the enhancement of the properties. Though, in this study, only a partial intercalation was achieved through continuous processing, it shows a possibility to produce nanocomposites by this approach. As this is a physical process that can be adapted to the conventional extrusion, the approach suggested in this study may be extended to other polymer/clay nanocomposite systems as well.