Stereoregular P(MMA)-clay nanocomposites by metallocene catalysts: In situ synthesis and stereocomplex formation

This contribution reports the synthesis and characterization of stereochemically controlled, as well as crystalline stereocomplex, P(MMA)‐clay nanocomposites using metallocene complexes and alane‐intercalated clay activators. The ligand elimination and exchange reactions involving Lewis acids E(C6F5)3 (E = Al, B) and an organically modified montmorillonite clay were employed to synthesize the alane‐intercalated clay activators. When combined with dimethyl metallocenes of various symmetries, these clay activators brought about efficient MMA polymerizations leading to in situ polymerized, stereochemically controlled P(MMA)‐intercalated clay nanocomposites. The most noticeable thermal property enhancement observed for the clay nanocomposite P(MMA), when compared with the pristine P(MMA) having similar molecular weight and stereomicrostructure, has a considerable increase in Tg (≥10 °C). Mixing of dilute THF solutions of two diastereomeric nanocomposites in a 1:2 isotactic to syndiotactic ratio, followed by reprecipitation or crystallization procedures, yielded unique double‐stranded helical stereocomplex P(MMA)‐clay nanocomposites with a predominantly exfoliated clay morphology. Remarkably, the resulting crystalline stereocomplex P(MMA) matrix is resistant to the boiling‐THF extraction and its clay nanocomposites exhibit high Tm of 201 to 210 °C. Furthermore, the stereocomplex P(MMA)‐clay nanocomposite shows a one‐step, narrow decomposition temperature window and a single, high maximum rate decomposition temperature of 377 °C. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 2581–2592, 2007 Stereochemically controlled and crystalline stereocomplex P(MMA)–clay nanocomposites have been synthesized using metallocene complexes of various symmetries and two types of alane‐intercalated clay activators.