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JOURNAL OF

COMPOSITE
Article M AT E R I A L S
Journal of Composite Materials
46(10) 1139–1150
! The Author(s) 2012
Effect of modified clay on mechanical Reprints and permissions:
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and morphological properties of ethylene DOI: 10.1177/0021998311413686
jcm.sagepub.com
octane copolymer–polypropylene
nanocomposites

SK Sharma1, Ajay K Nema2 and SK Nayak1

Abstract
Ethylene octane copolymer–polypropylene (PP) blend was optimized at 30 wt% of ethylene octane copolymer with PP
and the same ratio was kept constant for preparing ethylene octane copolymer–PP nanocomposites (70/30). The
nanocomposites were prepared with commercially modified organoclays (C20A and C30B) and laboratory-modified
organoclays (OMMT-I and OMMT-II) in the ratio of 3, 5, and 7 wt%. The compatibilizer polypropylene-grafted maleic
anhydride (PP-g-MA) was used to get the exfoliated nanocomposites in the ratio of 5, 10, and 15 wt% for C20A, C30B,
OMMT-I, and OMMT-II nanocomposites. X-ray diffraction (XRD) and transmission electron microscopy (TEM) results
indicated the formation of well-exfoliated morphology at 5 wt% of organoclay and 5 wt% of PP-g-MA compatibilizer. The
increase in tensile properties due to the reinforcing effect imparted by organoclays along with high aspect ratio of the clay
pallets allowed a greater degree of stress transfer at the interface.

Keywords
Montmorillonite (MMT), polypropylene maleic anhydride (PP-g-MA)

Introduction filler are widely used to produce automotive exterior


The use of layered silicates as fillers in polymers has and interior parts; however, the use of large amounts
gained considerable amount of attention due to the of filler, for example, 20 wt%, which is required to
ability to achieve exceptional property enhancements achieve desirable properties, results in some processing
at very low loading levels.1–4 In recent years, a con- and performance compromises as described earlier. In
certed effort has been made to disperse layered silicates addition, it has been reported that the morphology of
in low-cost polyolefins, like polypropylene (PP).5–15 PP the dispersed phases plus elastomer, filler contents as
has many desirable properties, such as low density, high well as processing conditions play an important role in
thermal stability, and good solvent resistance; however, determining the stiffness and toughening behavior of
its modulus relative to engineering polymers, for exam- PP–elastomer–filler composites.23,25,26 In this article,
ple, nylon 6, polycarbonate, is low.16 This issue is often ethylene octane copolymer–PP blend was optimized at
addressed by adding conventional fillers, for example, 30 wt% of ethylene octane copolymer with PP and the
talc or glass fibers.17–20 Unfortunately, due to the size
(or aspect ratio) of such fillers, large loadings are 1
Central Institute of Plastic Engineering and Technology, Chennai, India
required to significantly increase stiffness, which can 2
Central Institute of Plastic Engineering and Technology, Bhopal India
result in poor processability, lower ductility, and a
rough surface finish. The latter has been a major issue Corresponding authors:
for some applications in which an optimum balance of SK Nayak, Central Institute of Plastics Engineering and Technology,
stiffness and toughness is desired; to address this, an Guindy, Chennai 600 032, India
elastomer component has been incorporated into Email: drsknayak@yahoo.com
SK Sharma, Central Institute of Plastics Engineering and Technology,
PP–filler composites, producing ternary-phase polymer Guindy, Chennai 600 032, India
composites.21–25 Elastomer-toughened PP or thermo- Ajay K Nema, Central Institute of Plastics Engineering and Technology,
plastic olefine (TPO) materials containing talc as a Bhopal – 462 023, India

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1140 Journal of Composite Materials 46(10)

same ratio was kept constant for preparing ethylene was dispersed in 4500 mL of distilled water with
octane copolymer–PP nanocomposites. The nanocom- vigorous stirring at 80 C in a glass vessel to pre-
posites were prepared with organically modified nano- pare Na-MMT dispersion. Excessive amount of
clay (C20A, C30B, OMMT-I, and OMMT-II) in the p-amino benzoic acid with molar ratio of 1:0.17
ratio of 3, 5, and 7 wt%. The compatibilizer polypro- acidified by appropriate amount of concentrated
pylene-grafted maleic anhydride (PP-g-MA) was used HCl was dispersed into 600 mL of distilled water
to get the exfoliated nanocomposites in the ratio of 5, to prepare p-amino benzoic acid acidified solution.
10, and 15 wt% for C20A, C30B, OMMT-I, and Subsequently, the solution was added to Na-MMT
OMMT-II nanocomposites. The objective of the article dispersion and resultant suspension was vigorously
is to get the optimum level of desired mechanical prop- stirred at 80 C for 4 h. On titration of the filtrate
erties with highest degree of exfoliation of organoclay with 0.1 N AgNO3, the treated Na-MMT was
with high impact properties. washed thoroughly with water until no AgCl pre-
cipitate occurred at room temperature. Finally, the
filtrates were dried at 80 C for 12 h in vacuum,
ground, and screened with a 325-mesh sieve to
Experimental obtain p-amino benzoic acid treated clay
Materials and sample preparation (OMMT-I).
(d) Na-MMT was modified using octadecylamine
(a) The PP injection molding grade (RepolÕ H110MA) employing a method reported by Han et al.28 One
was obtained from M/s Reliance Industries hundred and eighty grams of Na-MMT with CEC
Ltd, Mumbai, India. The melt flow index (MFI) 92.6 meq/100 g was dispersed in 2500 mL of distilled
(at 230 C/2.16 kg) was 11 g/10 min and density water with vigorous stirring at 80 C in a glass vessel
0.92 g/cc. The TPO (ethylene octane copolymer) to prepare Na-MMT dispersion. Excessive amount
was procured from ExxonMobil Chemical, of octadecylamine with molar ratio of 1:0.4 acidified
Singapore under trade name EXACTÕ by appropriate amount of concentrated HCl was
Plastomers, unreinforced, high flow, medium dispersed into 500 mL of distilled water to prepare
impact general-purpose grade, and had MFI 1.1. octadecylamine acidified solution. Subsequently,
PP-g-MA was procured in the form of granules the solution was added to Na-MMT dispersion
from M/s ExxonMobil Chemical, Singapore under and resultant suspension was vigorously stirred at
the trade name EXXELORÕ 1015. The grafting per- 80 C for 8 h. On titration of the filtrate with 0.1 N
centage reported as 0.5 wt% with MFI of 150 g/ AgNO3, the treated Na-MMT was washed thor-
10 min and specific gravity 0.882 g/cc. oughly with water until no AgCl precipitate
(b) Three types of commercially produced clays, occurred at room temperature. Finally, the filtrates
untreated (Na-MMT), treated (Cloisite 20A and were dried at 80 C for 12 h in vacuum, ground, and
Cloisite 30B) were procured from M/s Southern screened with a 325-mesh sieve to obtain octadecy-
Clay Products, USA. The other two types of orga- lamine-treated clay (OMMT-II).
noclays, OMMT-I and OMMT-II, were modified in
the laboratory using Na-MMT nanoclay. Nanoclay
Na-MMT had specific gravity 2.86 g/cc and base Preparation of ethylene octane copolymer–PP blend
spacing (d001) 11.7 Å with modifier concentration
of 92.6 meq/100 g clay having less than 2% of mois-
and their nanocomposites
ture content. The treated clay C20A had specific The blends of iPP with TPO (ethylene octane copoly-
gravity of 1.77 g/cc and base spacing (d001) 24.2 Å mer) thermoplastic elastomer were prepared using
with modifier concentration of 95 meq/100 g clay twin-screw extruder in the ratio of 75/30 wt% of
having less than 2% moisture content. The other iPP–TPO. Melt-processing conditions play a key role
treated clay C30B had specific gravity of 1.98 g/cc in achieving high levels of exfoliation. Indeed, polymer
and base spacing (d001) 18.5 Å with modifier concen- nanocomposites have been formed using a variety of
tration of 95 meq/100 g clay having less than 2% shear devices (e.g., extruders, mixers, ultrasonicators),
moisture content. The C20A and C30B clays were among which twin-screw extruders have proven to be
used with 3, 5, and 7 wt%; and PP-g-MA compati- most effective for the exfoliation and dispersion of sil-
bilizer was used with 5, 10, and 15 wt%. icate layers.29 Study on melt blending of iPP–TPO/
(c) Na-MMT was modified using p-amino benzoic 5wt%Na-MMT was carried out using Berstorff, ZE
acid employing a method reported by Zhu.27 One 25 (Germany) having the L/D ratio 48:1, which is a
hundred and eighty grams of Na-MMT with self-wiping co-rotating twin-screw extruder, and tem-
cation exchange capacity (CEC) 92.6 meq/100 g perature profile used was 180–240 C (feed zone to die

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Sharma et al. 1141

zone) with various rotor speeds, 100, 150, and 200 rota- 2.54 mm notch, 45 notch angle as per ASTM D
tion per minute (rpm). The resultant iPP–TPO nano- 256 with the specimen size of 6.23  12.7  3 mm.
composites were evaluated for tensile strength, tensile (d) The morphological properties of the nanocompo-
modulus, flexural strength, flexural modulus, and Izod sites were observed by scanning electron microscope
impact strength. (SEM) and transmission electron microscope
(TEM). The state of dispersion of the filler in the
polymer blends was assessed by TEM imaging using
Compositions Philips CM 20 instrument, Canada. The ultra-thin
The compositions prepared for the iPP–TPO nanocom- sections (~50 nm) were cut from the central part of
posites are given in Table 1. the injection molded bars in the direction of the
flow under cryogenic condition; the samples were
stained with 4 wt% lead citrate to enhance the
Testing and analytical instrumentation phase contrast between the PP and elastomer
phase. The phase morphology of impact fracture
(a) The tensile properties were measured as per ASTM specimen of nanocomposites was studied using
D 638 standard with specimen size 165  13  SEM (JEOL-6360). It is used to determine the
3 mm, a gage length of 50 mm, and cross-head shape and the size of in-situ formed nanoparticles.
speed of 50 mm/min and then the properties were A distribution was obtained from micrographs. The
studied using LR 100K, Lloyds Instrument Ltd, high-electron voltage of 1 eV was used and sample
UK. was coated with copper to avoid charging.
(b) Flexural properties were measured as per the (e) X-ray diffraction (XRD) was carried out to exam-
ASTM D 790 with specimen size 127  12.7  ine the basal spacing (d001) of the pure clay as well
6 mm, a gage length of 50 mm, and cross-head as nanocomposites using Scifert 2002, Japan, at
speed of 1.3 mm/min and then the properties were operating voltage 45 kV, current 40 mA, and wave-
studied using Universal Tester (LR 100K, Lloyds length 0.154 nm. The samples were scanned over
Instrument Ltd, UK). the range 2 ¼ 2 –10 and measurements were
(c) The notched Izod impact strength of specimen was recorded at every 0.03 interval and basal (d001)
measured using impactometer (Ceast, Italy) with spacing was calculated using n ¼ 2d sin .

Table 1. iPP–TPO nanocomposite compositions and designations

S. no. Designations Type of nanoclay phr of nanoclay phr of compatibilizer

1 iPP–TPO virgin – – –
2 iPP–TPO/3wt%Na-MMT Na-MMT 3 –
3 iPP–TPO/5wt%Na-MMT Na-MMT 5 –
4 iPP–TPO/7wt%Na-MMT Na-MMT 7 –
5 iPP–TPO/3wt%C20A C20A 3 –
6 iPP–TPO/5wt%C20A C20A 5 –
7 iPP–TPO/7wt%C20A C20A 7 –
8 iPP–TPO/3wt%C30B C30B 3 –
9 iPP–TPO/5wt%C30B C30B 5 –
10 iPP–TPO/7wt%C30B C30B 7 –
11 iPP–TPO/5wt%C20A/5wt%PP-g-MA C20A 5 5
12 iPP–TPO/5wt%C20A/10wt%PP-g-MA C20A 5 10
13 iPP–TPO/5wt%/C20A/15wt%PP-g-MA C20A 5 15
14 iPP–TPO/5wt%/C30B/5wt%PP-g-MA C30B 5 5
15 iPP–TPO/5wt%/C30B/10wt%PP-g-MA C30B 5 10
16 iPP–TPO/5wt%/C30B/15wt%PP-g-MA C30B 5 15
17 iPP–TPO/5wt%OMMT-I OMMT-I 5 –
18 iPP–TPO/5wt%OMMT-II OMMT-II 5 –
19 iPP–TPO/5wt%OMMT-I/5wt%PP-g-MA OMMT-I 5 5
20 iPP–TPO/5wt%OMMT-II/5wt%PP-g-MA OMMT-II 5 5

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1142 Journal of Composite Materials 46(10)

Results and discussion to the reinforcing characteristics of dispersed Na-MMT


Mechanical properties of iPP–TPO/Na-MMT nanoclay with high aspect ratio. However, the tensile
strength and its modulus, flexural strength and its mod-
nanocomposites
ulus are lower for 7 wt%/Na-MMT clay loading in
The mechanical properties, that is, tensile strength, ten- comparison with that of 5 wt% Na-MMT. Decrease
sile modulus, flexural strength, flexural modulus of in tensile strength and its modulus, flexural strength
iPP–TPO/5wt%Na-MMT nanocomposites prepared and its modulus of the nanocomposites beyond 5 wt%
at 100 rpm are comparatively higher than those pre- Na-MMT clay loading is due to filler–filler interaction.
pared at 150 rpm and 200 rpm. Probably at higher rota- This interaction results in the formation of agglomer-
tion of twin-screw extruder beyond 100 rpm (i.e., ates and induced local stress concentration in the nano-
150 rpm and 200 rpm) the residence time reduces and composites and leads to the reduction in the clay aspect
shear rate increases, which have resulted in poor mixing ratio, thereby reducing the contact surface area
and dispersion. As reported by Verghese et al.,29 twin between the clay and the iPP–TPO matrix.30
screw at appropriate shear rate and residence time
appears to provide the best mixing in terms of disper-
sion and exfoliation. The mechanical properties of
Mechanical properties of iPP–TPO nanocomposites
iPP–TPO/5wt%Na-MMT prepared in twin-screw Tensile properties. Although iPP–TPO matrix has
extruder at 100 rpm is optimum due to moderate shown reduction in tensile strength, tensile modulus,
shear rate and residence time in twin-screw extruder. flexural strength, and flexural modulus (Table 3) in
Three compositions of Na-MMT (3, 5, and 7 wt%) comparison with that of iPP virgin matrix, it has sig-
with iPP–TPO were evaluated for mechanical proper- nificantly gained in impact strength. The decrease in the
ties using Universal Testing Machine (UTM, Lloyd LR tensile strength and modulus is 24.4% and 72.9% and
100K and Impact testing machine of ATS FAAR). The in the flexural strength and modulus it is 54.7% and
results obtained are given in Table 2. 54.9%, respectively; the improvement in the impact
Tensile properties of virgin iPP–TPO and its nano- strength is 207%. This development makes iPP–TPO
composites with Na-MMT as a function of clay load- material of choice to have very good impact strength
ing in weight percentage, given in Table 1, were with the little compromise in other mechanical proper-
evaluated for the reinforcing benefits of nanoclay in ties. The study on nanocomposites of iPP–TPO will
the iPP–TPO matrix. The tensile strength and its certainly be useful to see how the reinforcement effect
modulus, flexural strength and its modulus are increas- will improve the mechanical properties of nanocompo-
ing with Na-MMT clay loading from 3 to 5 wt%. sites keeping the impact properties at same level or
The iPP–TPO/5wt%Na-MMT nanocomposites have improving further.
optimum values from 3 to 7 wt% iPP–TPO/Na-MMT Tensile properties of virgin iPP–TPO and its nano-
nanocomposites. The iPP–TPO/5wt%Na-MMT show- composites with different commercially modified clay
ing tensile strength 26.5 MPa, tensile modulus 202.1 viz C20A, C30B and laboratory-modified clay viz
MPa, flexural strength 24 MPa, and flexural modulus OMMT-I, OMMT-II with compatibilizer (PP-g-MA)
871.5 MPa. There is an increase of 10.2% in tensile were evaluated for the reinforcing benefits of nanoclay
strength, 13.4% in tensile modulus, 20.6% in flexural into the iPP–TPO matrix. It is observed that the tensile
strength, and 31.6% in flexural modulus in comparison strength and modulus increase linearly with loading
with that of virgin iPP–TPO (Table 2). By examining 3–5 wt% of C20A and C30B clay. There is an increase
the mechanical properties’ dependence on clay loading, of 23.7% in tensile strength and 40.7% in tensile mod-
it is revealed that the increase in tensile strength and its ulus of iPP–TPO/5wt%C20A nanocomposites in com-
modulus, flexural strength and its modulus attributed parison with that of virgin iPP–TPO. In case of

Table 2. Mechanical properties of various compositions of iPP–TPO/Na-MMT

Tensile strength Tensile modulus Flexural strength Flexural modulus Impact strength
S. no. Specimen designation (MPa) (MPa) (MPa) (MPa) (J/m)

1 iPP–TPO virgin 24.4  0.48 178.1  0.48 19.9  0.45 662.2  0.48 81.4  0.58
2 iPP–TPO/3wt%Na-MMT 25.1  0.54 194.7  0.68 21.5  0.45 681.2  0.21 91.2  0.58
3 iPP–TPO/5wt%Na-MMT 26.5  0.48 202.1  0.18 24.0  0.65 871.5  0.19 109.7  0.21
4 iPP–TPO/7wt%Na-MMT 24.7  0.48 187.0  0.12 19.0  0.45 659.5  0.45 82.4  0.45
Note:  indicates the standard deviation.

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Sharma et al. 1143

Table 3. Mechanical properties of iPP–TPO nanocomposites

S. Tensile strength Tensile modulus Flexural strength Flexural modulus Impact strength
no. Specimen designation (MPa) (MPa) (MPa) (MPa) (J/m)

1 iPP–TPO virgin 24.4  0.45 178.1  0.28 19.9  0.78 662.2  0.25 81.4  0.45
2 iPP–TPO/3wt%C20A 27.8  0.45 210.4  0.48 25.8  0.48 890.2  0.58 113.7  0.45
3 iPP–TPO/5wt%C20A 30.2  0.78 250.6  0.59 30.0  0.14 1050.0  0.45 124.5  0.21
4 iPP–TPO/7wt%C20A 28.0  0.58 220.5  0.54 27.2  0.51 895.2  0.65 112.0  0.47
5 iPP–TPO/3wt%C30B 27.1  0.57 200.5  0.26 24.0  0.51 895.2  0.12 11.2  0.58
6 iPP–TPO/5wt%C30B 28.4  0.47 215.3  0.58 27.3  0.46 968.0  0.12 118.5  0.58
7 iPP–TPO/7wt%C30B 27.0  0.48 202.5  0.54 25.5  0.45 935.8  0.21 109.8  0.58
8 iPP–TPO/5wt%C20A/5wt%PP-g-MA 38.4  0.24 278.5  0.58 38.1  0.58 1198.0  0.6 321.7  0.34
9 iPP–TPO/5wt%C20A/10wt%PP-g-MA 29.6  0.48 259.2  0.14 35.3  0.73 1078.7  0.45 281.5  0.54
10 iPP–TPO/5wt%/C20A/15wt%PP-g-MA 28.3  0.68 250.8  0.58 31.1  0.41 1060.5  0.58 211.6  0.16
11 iPP–TPO/5wt%/C30B/5wt%PP-g-MA 34.2  0.48 230.2  0.98 28.5  0.89 1056.4  0.48 279.5  0.87
12 iPP–TPO/5wt%/C30B/10wt%PP-g-MA 29.1  0.58 205.4  0.48 26.3  0.16 801.4  0.56 210.7  0.58
13 iPP–TPO/5wt%/C30B/15wt%PP-g-MA 25.5  0.89 198.5  0.89 24.6  0.21 745.5  0.58 195.2  0.51
14 iPP–TPO/5wt%OMMT-I 27.9  1.29 244.8  0.48 27.2  0.45 1020.4  0.45 118.7  0.45
15 iPP–TPO/5wt%OMMT-II 26.9  0.47 228.5  0.15 25.2  0.15 967.4  0.43 106.9  0.23
16 iPP–TPO/5wt%OMMT-I/5wt%PP-g-MA 35.1  0.87 270.5  0.35 36.2  0.45 1157.6  0.48 266.8  0.48
17 iPP–TPO/5wt%OMMT-II/5wt%PP-g-MA 30.8  0.28 255.3  0.47 31.4  0.45 1054.5  0.61 249.7  0.48
Note:  indicates the standard deviation.

iPP–TPO/5wt%C30B there is an increase of 16.3% in at laboratory using p-amino benzoic acid, designated
tensile strength and 20.8% in tensile modulus in com- as OMMT-I27 and octadecylamine, designated as
parison with that of virgin iPP–TPO. Whereas the OMMT-II.28 Furthermore, the nanocomposites pre-
iPP–TPO/5wt%Na-MMT showed 10.2% increase in pared using OMMT-I and OMMT-II showed simi-
tensile strength and 13.4% in tensile modulus in com- lar tensile strength and modulus. The tensile strength
parison with that of virgin iPP–TPO. This is probably and modulus of iPP–TPO/5wt%OMMT-I are 27.9
due to iPP–TPO/5wt%C20A and iPP–TPO/5wt% MPa and 244.8 MPa and tensile strength and modulus
C30B nanocomposites having immobilized or partially of iPP–TPO/5wt%OMMT-II are 26.9 MPa and 228.5
mobilized phase as a consequence of interaction of MPa. On comparison tensile properties of iPP-TPO/
organic modification of clays and large number of 5wt%OMMT-I with iPP-TPO/5wt%C20A it was
interacting molecules due to dispersed phase volume found that both are having similar values indicate the
ratio characteristics of largely intercalated/exfoliated similar CEC for OMMT-I and C20A respectively that is
nanocomposites. Further increase in loading of C20A 95 meq/100g and the similar properties was observed for
in iPP–TPO/C20A nanocomposite, that is, 7 wt% is iPP-TPO/5wt% OMMT-II with iPP-TPO/5wt% C30B
giving lower values of tensile strength and modulus. with CEC of 90 meq/100 g.
The tensile strength and modulus of iPP–TPO/7wt% While comparing the results obtained for tensile
C20A are 28 MPa and 220.5 MPa. The decrease in ten- strength and modulus of iPP–TPO/5wt%C20A nano-
sile strength and modulus is due to the filler–filler inter- composites with iPP–TPO/5wt%C30B it is established
action, which results in agglomerates and induced that the nanocomposites of C20A are giving higher
local stress concentration in the nanocomposites and value for tensile strength and modulus than those of
leads to reduction in clay aspect ratio thereby reducing C30B. The primary cause for such higher values is
the contact surface between the C20A and iPP–TPO attributed to the modifier, which has higher CEC.31,32
matrix. Similarly comparing the results obtained for tensile
Commercially modified clays C20A and C30B strength and modulus of iPP–TPO/5wt%OMMT-I
taken for the reinforcement studies are organically mod- nanocomposites with iPP–TPO/5wt%OMMT-II it is
ified with dimethyl-dehydrogenated tallow quaternary established that the nanocomposites of OMMT-I are
ammonium chloride and methyl, tallow, bis-2-hydroxy- giving higher value for tensile strength and modulus
ethyl, quaternary ammonium (MT2EtOH), respectively. than those of OMMT-II. The primary cause for such
The CEC of C20A is 95 meq/100 g and C30B higher values is also attributed to the modifier, which
is 90 meq/100 g. Na-MMT nanoclay was modified has better CEC.31,32

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1144 Journal of Composite Materials 46(10)

Matrix iPP–TPO is nonpolar therefore synthesis of The compatibilizer PP-g-MA contains 0.5 wt% of
well-exfoliated nanocomposites appears to be more dif- grafted maleic anhydride. Generally PP-g-MA is pre-
ficult, because this polymer is so hydrophobic and lacks pared by the process of free radical maleic anhydride
suitable interactions with the clay surface, even after it grafting onto PP backbone chain.36 During this pro-
has been organically modified in comparison with polar cess, PP chain scission is accompanied; consequently
polymers, like polyamides, that can effectively exfoliate the lower molar mass of corresponding PP-g-MA is
organically modified clays using conventional melt-pro- produced. High content of such an oligomer in the
cessing techniques. composites can adversely affect mechanical perfor-
To obtain iPP–TPO/C20A, iPP–TPO/C30B, iPP– mance. In other words, a large portion of low molar
TPO/OMMT-I, and iPP–TPO/OMMT-II nanocompo- mass compatibilizer formed a matrix phase together
sites well exfoliated by melt blending the modified with neat iPP–TPO matrix. Moreover, incompatibility
oligomer was added. The small amount of a maleic problems between matrix iPP–TPO and PP-g-MA
anhydride grafted PP (PP-g-MA) that is miscible with could arise at this high maleic anhydride content of
the base iPP–TPO matrix was used as a compatibilizer. compatibilizer. So, moderate maleic anhydride content
The PP-g-MA is used to mediate the polarity between and higher compatibilizer molar mass would be
the clay surface and the iPP–TPO matrix. Morawiec required to improve the toughness/stiffness balance of
et al.33 and others established that the polar character such nanocomposites. On further addition of PP-g-MA
of the anhydride has an affinity for the clay materials, beyond 5 wt% there is decrease in tensile properties of
such that the maleated PP can serve as a ‘compatibi- iPP–TPO nanocomposites. This reduction is attributed
lizer’ between the matrix and the filler.34,35 to excess quantity of compatibilizer PP-g-MA, which
The PP-g-MA compatibilizer was added 5, 10, 15, gives plasticizing effect in nanocomposites. Hence,
and 20 wt% with iPP–TPO/5wt%C20A, iPP–TPO/ there is a reduction in tensile strength and modulus.
5wt%C30B, iPP–TPO/5wt%OMMT-I, and iPP–TPO/
5wt%OMMT-II to obtain fully exfoliated nanocompo-
sites. It is observed that the tensile strength and Flexural properties. The variation of flexural proper-
modulus increase with the addition of 5 wt% compatibi- ties of iPP–TPO nanocomposites along with virgin
lizer (PP-g-MA). In case of iPP–TPO/5wt%C20A/5wt% iPP–TPO matrix vs. clay loading is summarized in
PP-g-MA tensile strength and modulus are 38.4 MPa Table 3. As observed from Table 2, the flexural strength
and 278.5 MPa. The similar trend was observed for and modulus show a similar trend as in the case of tensile
the iPP–TPO/5wt%C30B/5wt%PP-g-MA, iPP–TPO/ properties. The flexural strength of the nanocomposites
5wt%OMMT-I/5wt%PP-g-MA, and iPP–TPO/5wt% with C20A and C30B nanoclays showed an optimum
OMMT-II/5wt%PP-g-MA nanocomposites. In case value at 5 wt% clay loading, beyond which there is
of iPP–TPO/5wt%C30B/5wt%PP-g-MA nanocompo- decline in the strength. This behavior is probably due
sites tensile strength and tensile modulus are 34.2 to the presence of clay particle that possibly acted as
MPa and 230.2 MPa. The iPP–TPO/5wt%OMMT-I/ stress concentration site and caused a reduction in the
5wt%PP-g-MA and iPP–TPO/5wt%OMMT-II/5wt% flexural strength of the nanocomposites. The flexural
PP-g-MA nanocomposites showed tensile strength and strength and modulus of iPP–TPO/5wt%C20A and
tensile modulus of 35.1 MPa, 270.5 MPa and 30.8 MPa, iPP–TPO/5wt%C30B nanocomposite are 30 MPa,
255.3 MPa, respectively. It is observed that tensile 1050 MPa and 27.3 MPa, 968 MPa, respectively. There
strength and modulus are optimum in iPP–TPO/5wt% is an increase in flexural strength and modulus of
C20A/5wt%PP-g-MA, iPP–TPO/5wt%C30B/5wt%PP- iPP–TPO/5wt%C20A nanocomposites, that is, 50.7%
g-MA, iPP–TPO/5wt%OMMT-I/5wt%PP-g-MA, and and 58.56% as compared with that of iPP–TPO virgin.
iPP–TPO/5wt%OMMT-II/5wt%PP-g-MA among all Similarly, iPP–TPO/5wt%/C30B nanocomposites
the nanocomposites prepared using various composition showed increase in flexural strength and modulus, that
of organically modified clay (C20A, C30B, OMMT-I, is, 37.1% and 46.1% as compared with iPP–TPO virgin,
OMMT-II) and compatibilizer (PP-g-MA). It indicates whereas the iPP–TPO/5wt%Na-MMT nanocomposites
that these nanocomposites have well-exfoliated struc- showed only 20.6% increase in flexural strength and
ture. The nanoclay is ion exchanged (modified) to 31.6% flexural modulus in comparison with that of
reduce the cohesive force between the clay platelets. virgin iPP–TPO. This is probably due to iPP–TPO/
The compatibilizer (PP-g-MA) chemically modifies the 5wt%C20A and iPP–TPO/5wt%C30B nanocomposites
iPP–TPO and improves adhesion between the iPP–TPO having immobilized or partially mobilized phase as a
matrix and nanoclay filler, whereas the modified clays consequence of interaction of organic modification of
C20A, C30B, OMMT-I, and OMMT-II promote the clays and large number of interacting molecules due to
ion exchange, which enhances exfoliation and better dispersed phase volume ratio characteristics of largely
dispersion. intercalated/exfoliated nanocomposites.

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Sharma et al. 1145

Flexural strength and modulus of iPP–TPO/7wt% polymer matrix and the clay filler. Compatibilizer (PP-
C20A and iPP–TPO/7wt%C30B nanocomposites are g-MA) chemically modifies the iPP–TPO and improves
27.2 MPa, 895.2 MPa and 27.3 MPa, 968.10 MPa, adhesion between the iPP–TPO matrix and clay filler,
respectively. The decrease in flexural strength and mod- whereas the modified clays C20A, C30B, OMMT-I, and
ulus beyond 5 wt% loading of C20A nanoclay is due to OMMT-II promote the ion exchange, which enhances
the filler–filler interaction, which results in agglomer- exfoliation and better dispersion.
ates and induced local stress concentration in the nano-
composites and leads to reduction in clay aspect ratio Impact properties. The impact strength of virgin
thereby reducing the contact surface between the C20A iPP–TPO and its nanocomposites is also enumerated
and iPP–TPO matrix.37 in Table 3. It is of iPP–TPO/5wt%C20A increased
Flexural strength and modulus of iPP–TPO/5wt% from 3 wt% to 5 wt% of C20A loading and decreased
OMMT-I nanocomposites and iPP–TPO/5wt% slightly on further addition of 7 wt% C20A. The impact
OMMT-II nanocomposites also showed 36.6%, 54.0% strength of iPP–TPO/5wt%C20A and iPP–TPO/5wt%
and 26.6%, 46% increase, respectively, in comparison to C30B is showing the same values of 124.5 J/m that is
that of iPP–TPO virgin matrix. These results are very higher than that of iPP–TPO virgin, that is, 81.4 J/m. It
close to the results obtained for iPP–TPO/5wt%C20A was observed that for C20A there was 53% increase
and iPP–TPO/5wt%C30B nanocomposites. An increase upto 5wt% and further it was decreases whereas for
in flexural modulus by up to 5 wt% clay loading is attrib- C30B the 41.5% increase observed upto 5wt%. The
uted to the high stiffness of the nanoclay with high aspect increase in impact strength is about 53% up to 5 wt%
ratio. Beyond 5 wt% loading there is decrease in flexural C20A clay loading. The impact strengths of iPP–TPO/
modulus similar to the flexural strength. It is probably 5wt%OMMT-I and iPP–TPO/5wt%OMMT-II are
due to filler–filler interaction instead of filler–matrix 118.7 J/m and 106.9 J/m, respectively, which are
interaction, which also leads to formation of agglomer- higher than that of iPP–TPO virgin, that is, 81.4 J/m.
ates as reported by Rong et al.34 The increase in impact strength is about 45.7% and
The PP-g-MA compatibilizer was added 5, 10, 31.3% for iPP–TPO/5wt%OMMT-I and iPP–TPO/
and 15 wt% with iPP–TPO/5wt%C20A, iPP–TPO/ 5wt%OMMT-II. On addition of 5–15 wt% PP-g-MA
5wt%C30B, iPP–TPO/5wt%OMMT-I, and iPP–TPO/ the optimum value of impact strength of iPP–TPO/
5wt%OMMT-II to obtain fully exfoliated nanocompo- 5wt%C20A/5wt%PP-g-MA is 321.7 J/m. The increase
sites. It is observed that the flexural strength and in the impact strength of iPP–TPO/5wt%C20A/5wt%
modulus increase at 5 wt% with the addition of PP-g-MA is about 295%. The similar results are found
compatibilizer (PP-g-MA). In case of iPP–TPO/5wt% for iPP–TPO/5wt%C30B/5wt%PP-g-MA, iPP–TPO/
C20A/5wt%PP-g-MA flexural strength and modulus 5wt%OMMT-I/5wt%PP-g-MA, and iPP–TPO/5wt%
are 38.1 MPa and 1198 MPa. The similar trend was OMMT-II/5wt%PP-g-MA, that is, 279.5 J/m, 266.8
observed for the iPP–TPO/5wt%C30B/5wt%PP-g- J/m, and 249.1 J/m, respectively. The iPP–TPO/5wt%
MA, iPP–TPO/5wt%OMMT-I/5wt%PP-g-MA, and C20A/5wt%PP-g-MA reported the highest impact
iPP–TPO/5wt%OMMT-II/5wt%PP-g-MA nanocom- strength among all the nanocomposites. There is an
posites. In case of iPP–TPO/5wt%C30B/5wt%PP-g- increase in the impact strength with the increase in
MA nanocomposites flexural strength and flexural organoclay in the presence of PP-g-MA compatibilizer
modulus are 28.5 MPa and 1056.4 MPa. The iPP–TPO/ due to change in behavior from brittle to ductile at
5wt%OMMT-I/5wt%PP-g-MA and iPP–TPO/5wt% higher TPO content, that is 25 wt%.38 This behavior
OMMT-II/5wt%PP-g-MA nanocomposites showed is studies by Paul et al.38 and they established the influ-
flexural strength and flexural modulus of 36.2 MPa, ence of organoclay and elastomer content on notched
1156.6 MPa and 31.4 MPa, 1054.5 MPa, respectively. Izod impact strength. For nanocomposites containing
It is observed that flexural strength and modulus up to 20 wt% elastomer, the addition of organoclay
are optimum in iPP–TPO/5wt%C20A/5wt%PP-g- leads to a decrease in the Izod values for nanocompo-
MA, iPP–TPO/5wt%C30B/5wt%PP-g-MA, iPP–TPO/ sites with no elastomer or a slight increase for nano-
5wt%OMMT-I/5wt%PP-g-MA, and iPP–TPO/5wt% composites with elastomer; these materials are
OMMT-II/5wt%PP-g-MA among all the nanocompo- relatively brittle and exhibit complete breakage of the
sites prepared using various composition of organically specimen during the impact test. However, at higher
modified clay (C20A, C30B, OMMT-I, OMMT-II) and amounts of elastomer, for example, 25% and 40%,
compatibilizer (PP-g-MA). It indicates that these nano- and as the amount of organoclay exceeds a certain
composites have well-exfoliated structure. The clay is ion value, it is generally expected that an increase in filler
exchanged (modified) to reduce the cohesive force content results in the fracture behavior changes from
between the clay platelets.37 The iPP–TPO matrix is brittle to ductile. It is generally expected that an
chemically modified to improve adhesion between the increase in the amount of filler results in a decrease in

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1146 Journal of Composite Materials 46(10)

impact strength of composite materials; however, the MA nanocomposites is given in Figure 2(a–e). The
trend is opposite for these nanocomposites, that is, value of diffraction peaks angle and corresponding
the impact strength increases with increasing organo- d-spacing of the nanocomposites is enumerated in
clay content. This unexpected behavior can be Table 5.
explained in terms of morphological changes induced The diffraction peak angle for iPP–TPO/5wt%
by the dispersion of clay particles. A mechanical brit- Na-MMT was obtained at 2 ¼ 6.13 , which corre-
tle–ductile transition generally can be induced either by sponds to interlayer d-spacing of 14.4 Å indicating an
increasing elastomer content or decreasing elastomer interacted nanostructure of iPP–TPO/Na-MMT nano-
particle size. A number of studies on the toughening composites. In this case, iPP–TPO could not have prop-
behavior of PP/rubber composites have suggested that erly intercalated into pristine montmorillonite, which
in addition to dispersed particle size and content, inter- may therefore have resulted in little dispersion of the
particle distance or matrix ligament thickness is also an Na-MMT nanoclay stacks in the iPP–TPO matrix rel-
important morphological parameter that affects the ative to the tightly stacked and much longer range
brittle–ductile transition of these systems.39–41 order in the case of Na-MMT. Whereas the diffraction
peak angle for iPP–TPO/5wt%C20A, iPP–TPO/5wt%
C30B nanocomposites was obtained at 2 ¼ 2.71 ,
Wide angle X-ray diffraction 4.82 , which corresponds to interlayer d-spacing 32.5
Wide angle X-ray diffraction (WAXD) of nanoclays Å and 18.3 Å, respectively, indicating the existence of
Na-MMT, C20A, C30B, OMMT-I and OMMT-II is both intercalated and exfoliated nanomorphologies.
shown in Figure 1(a–e). The value of diffraction
peaks’ angle and corresponding interlayer d001 spacing Table 4. Value of diffraction peaks and corresponding d-spacing
of the nanoclays is enumerated in Table 4. The diffrac- of nanoclay
tion peak angle for Na-MMT was obtained at 2 ¼
Specimen 2 d-Spacing
7.98 , which corresponds to interlayer d-spacing of S. no. Code designation (deg.) (Å)
11.7 Å, whereas the diffraction peak angle for C20A,
C30B, OMMT-I, and OMMT-II was obtained at 2 ¼ 1 A Na-MMT 7.98 11.7
2.94 , 5.61 , 3.71 , and 6.73 , which corresponds to 2 B C30B 5.61 18.5
interlayer d-spacing 24.2 Å, 18.5 Å, 23.7 Å, and 13.1 3 C C20A 2.94 24.2
Å, respectively. 4 D OMMT-I 3.71 23.7
WAXD of iPP–TPO/5wt%Na-MMT, iPP–TPO/ 5 E OMMT-II 6.73 13.1
5wt%C20A, iPP–TPO/5wt%C30B, iPP–TPO/5wt%
C20A/5wt%PP-g-MA, iPP–TPO/C30B/5wt%PP-g-

Figure 2. XRD of (A) iPP-TPO/5wt%Na-MMT, (B) iPP-TPO/


5wt%C20A, (C) iPP-TPO /5wt%C30B, (D) iPP-TPO /5wt%C20A/
Figure 1. XRD of (A) Na-MMT, (B) C20A, (C) C30B, (D) 5wt%PP-g-MA and (E) iPP-TPO /5wt%C30B/5wt.%PP-g-MA
OMMT-I and (E) OMMT-II Nanoclay. Nanocomposites.

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Sharma et al. 1147

Table 5. Values of diffraction peaks and corresponding


d-spacing of iPP-TPO/C20A and C30 B nanocomposites

2y d-Spacing
S. no. Code Specimen designation (deg.) (Å)

1 A iPP–TPO/5wt%Na-MMT 6.13 14.4


2 B iPP–TPO/5wt%C20A 2.71 32.5
3 C iPP–TPO/5wt%C30B 4.82 18.3
4 D iPP–TPO/5wt%C20A/ – –
5wt%PP-g-MA
5 E iPP–TPO/5wt%C30B/ – –
5wt%PP-g-MA

However, the absence of diffraction peak of iPP–TPO/


5wt%C20A/5wt%PP-g-MA and iPP–TPO/C30B/
5wt%PP-g-MA nanocomposites clearly indicates exfo-
liated nanomorphology in which maximum amount of
iPP–TPO matrix are entered into interlayers of the
C20A and C30B. The exfoliation of C20A with
PP-g-MA as compared with C30B with PP-g-MA indi- Figure 3. XRD of (A) iPP-TPO/5wt%Na-MMT, (B) iPP-TPO/
cates higher extent of favorable exfoliation. C20A and 5wt%OMMT-I (C) iPP-TPO/5wt%OMMT-II, (D) iPP-TPO/5wt%
C30B have the different organic modifier; grafting den- OMMTI/5wt%PP-g-MA and (E) iPP-TPO/5wt%OMMTII/5wt%
sity (equivalent to CEC) was higher in case of C20A (95 PP-g-MA Nanocomposites.
meq/100 g) than C30B (90 meq/100 g) and grafting
density per unit area of the C20A clay was higher by
factor of 95/90 ¼ 1.05. The peak from XRD studies for Table 6. Values of diffraction peaks and corresponding
all of the intercalated systems was narrow, indicating a d-spacing of iPP-TPO/OMMT-I and OMMT-II nanocomposites
high stacking order of the successive clay layers in the
2y d-Spacing
iPP–TPO matrix. The strong Bragg’s diffraction peaks
S. no. Code Specimen designation (deg.) (Å)
reflected coherent stacking of the clay platelets and,
thus the presence of an order structure in the iPP– 5 A iPP–TPO/5wt%Na-MMT 6.13 14.4
TPO nanocomposites. 2 B iPP–TPO/5wt%OMMT-I 3.10 28.4
WAXD of iPP–TPO/5wt%Na-MMT, iPP–TPO/ 4 C iPP–TPO/5wt%OMMT-II 5.31 16.6
5wt%OMMT-I, iPP–TPO/5wt%OMMT-II, iPP–TPO/ 1 D iPP–TPO/5wt%OMMT-I/ – –
5wt%OMMT-I/15wt%PP-g-MA, and iPP–TPO/5wt% 5wt%PP-g-MA
OMMT-II/15wt%PP-g-MA nanocomposites is given in 3 E iPP–TPO5wt%OMMT-II/ – –
Figure 3(a–e). The values of diffraction peak angle and 5wt%PP-g-MA
corresponding d-spacing of the nanocomposites are
enumerated in Table 6.
The diffraction peak angle for iPP/5wt%Na-MMT higher as compared with OMMT-II and indicates
nanocomposites was obtained at 2 ¼ 6.13 , which cor- favorable exfoliation. This behavior is probably due
responds to interlayer d-spacing of 14.4 Å. Whereas the to the polarity difference of OMMT-I and OMMT-II.
diffraction peak angle for iPP/5wt%OMMT-I and iPP/
5wt%OMMT-I nanocomposites was obtained at 2 ¼
Morphological properties
3.10 , 5.31 , which corresponds to interlayer d-spacing
28.4 Å and 16.6 Å, respectively, indicating the existence Transmission electron microscopy. TEM can further
of both intercalated and exfoliated nanomorphologies. validate and complement the results of WAXD. TEM
However, the absence of diffraction peak of iPP– micrographs of iPP–TPO/5wt%Na-MMT, iPP–TPO/
TPO/5wt%OMMT-I/5wt%PP-g-MA and iPP–TPO/ 5wt%C20A/5wt%PP-g-MA iPP–TPO/5wt%C30B/
OMMT-II/5wt%PP-g-MA nanocomposites clearly 5wt%PP-g-MA, iPP–TPO/5wt%OMMT-I/5wt%PP-g-
indicates the existence of exfoliated nanomorphology MA, and iPP–TPO/5wt%OMMT-II/5wt%PP-g-MA
in which maximum amount of iPP–TPO matrix entered nanocomposites with 5 wt% of nanoclays are shown
into interlayer of the OMMT-I and OMMT-II. The in Figure 4(a–d), respectively, where the dark area rep-
exfoliation of OMMT-I in presence of PP-g-MA is resents the clay and the gray/white area represent the

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1148 Journal of Composite Materials 46(10)

iPP–TPO matrix. It is clearly seen that in case of of the clay. The average particle size and their
iPP–TPO/5wt%C20A/5wt%PP-g-MA, iPP–TPO/5wt% corresponding aspect ratio were calculated using TEM
C30B/5wt%PP-g-MA, iPP–TPO/5wt%OMMT-I/5wt% micrograph. The average nanoparticle dimensions in
PP-g-MA, and iPP–TPO/5wt%OMMT-II/5wt%PP-g- nanocomposites are given in Table 7. In case of
MA [Figure 4(b–d)] the organic surfactant has played iPP–TPO/5wt%Na-MMT nanocomposites, the disper-
major role in dispersing the organoclay aggregates. sion of the clay particles was poor and many large
Higher the dispersion of the organoclay aggregates, aggregates of natural clay (in microns) are found to
larger will be the surface area of the silicates layers of bundle together. However, there are also large numbers
organoclay that becomes available for specific interac- of individual clay particles that are smaller than this
tions, that is, maleic anhydride group promoted the agglomerate. This confirms that the poor interaction
H-bonding with hydroxyl group of silicate that reduced between the iPP–TPO matrix polymer and Na-MMT
the interfacial tension. The above interaction between nanoclay would conglomerate to form large aggregate.
the polymer, nanoclay, and compatibilizer was studied
by Nascimento et al.42,43 The compatibilizer reduced
the viscosity and it also helped to reduce an interfacial Table 7. Average nanoparticle dimension in nanocomposites
tension between clay and polymer matrix. This phenom-
enon in turn increases the degree of dispersion (exfolia- Average Average Average
tion) of organoclay aggregates. This well-dispersed length thickness aspect
exfoliated morphology is attributed to the modification Nanoclays (nm), l (nm), t ratio (l/t)
of clay with dimethyl-dehydrogenated tallow quaternary Na-MMT 700  0.32 24  0.26 29  0.20
ammonium chloride (C20A), methyl, tallow, bis-2-hy- C20A 210  0.50 5  0.10 42  0.20
droxyethyl, quaternary ammonium (C30B), p-amino C30B 523  0.67 15  0.10 34  0.80
benzoic acid (OMMT-I), and octadecyalamine
OMMT-I 254  0.45 7  0.45 35  0.20
(OMMT-II), which lowers the electrostatic interaction
OMMT-II 560  0.85 18  0.23 31  0.56
between the clay layers, enlarges their intergallery spac-
ing, thus, facilitating exfoliation and efficient dispersion Note:  indicates the standard deviation.

Figure 4. (a) iPP-TPO/ 5wt%C20A/5wt%PP-g-MA (b) iPP-TPO/ 5wt%C30B/5wt%PP-g-MA (c) iPP-TPO/5wt% OMMT-I /5wt%
PP-g-MA (d) TEM micrographs of iPP-TPO/ 5wt% OMMT-II /5wt%PP-g-MA.

Downloaded from jcm.sagepub.com at The University of Iowa Libraries on March 16, 2015
Sharma et al. 1149

However, in case of iPP–TPO/5wt%C20A/5wt%PP-g- formation of partially/fully exfoliated structure of


MA nanocomposites, the C20A layers dispersed in the nanocomposites.
matrix are about 210 nm in length and 5 nm in thickness
corresponding to a highest aspect ratio of 4244 indicat-
ing an exfoliated nanostructure as compared with iPP– References
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