Rheological characterization of polystyrene–clay nanocomposites to compare the degree of exfoliation and dispersion

Polymer–clay nanocomposites are of great interest due to their improvement in certain material properties relative to virgin polymer or conventional composites. For example, compared to conventional materials, Nylon 6/montmorillonite nanocomposites demonstrated significant improvements, including high strength, high modulus and high heat distortion temperature. Because viscoelastic measurements are highly sensitive to the nanoscale and mesoscale structure of polymeric materials, when combined with X-ray scattering, electron microscopy, thermal analysis, and mechanical property measurements, they will provide fundamental understanding of the state and mechanism of exfoliation of the layered silicate (clay) in a polymer matrix. In addition, understanding rheological properties of polymer nanocomposites is crucial for application development and understanding polymer processability. The objective of this research is to develop a rheological technique to analyze the clay morphology in nanocomposite. Previous work has demonstrated the utility of the rheological technique to differentiate (qualify) the degree of exfoliation/dispersion. This report utilizes findings from the earlier work to further map out the structure-rheological response of polystyrene nanocomposites with various composition, clay types, and dispersion; and to quantify the key parameter that dominates the characteristic rheological response. This report explored a series of polystyrene (PS)–clay nanocomposites with 1,2-dimethyl-3-n-hexadecyl imidazolium (DMHDI) organically modified clays. These PS nanocomposites investigated here demonstrated a change of pattern in dynamic mechanical spectrum, as a function of the degree of exfoliation, from typical polymer response to a terminal response of [G′∼ω, G″∼ω], then to a pattern with double crossover frequencies, and finally to a solid-like response with G′>G″ in all frequency ranges. We showed that the number of particles per unit volume is a key factor determining the characteristic response of nanocomposites. In addition, the rheological response of PS–clays nanocomposite made from DMHDI modified clay combined with high-energy sonication (characterized as exfoliated by XRD and TEM) was compared with that of nanocomposites made by dimethyl, benzyl hydrogenated tallow (2MBHT) modified clay. We found that PS nanocomposites made by DMHDI-modified clay with high-energy sonication are better dispersed than the nanocomposites made previously using 2MBHT