Jing-Zhi
Zheng
a,
Xing-Ping
Zhou
a,
Xiao-Lin
Xie
*a and
Yiu-Wing
Mai
*b
aState Key Laboratory of Material Processing and Die & Mould Technology, School of Chemistry and Chemical Engineering, Huazhong University of Science and Technology, Wuhan 430074, China. E-mail: xlxie@mail.hust.edu.cn; Tel: +86-27-87540053
bCentre for Advanced Materials Technology (CAMT), School of Aerospace, Mechanical and Mechatronic Engineering J07, University of Sydney, Sydney, NSW 2006, Australia. E-mail: yiu-wing.mai@sydney.edu.au; Tel: +61-2-9351-2290
First published on 21st August 2010
Colloidal silica particles were synthesized by the sol–gel process and then modified with 3-methacryloxypropyltrimethoxysilane (γ-MPS) to induce vinyl groups on the surface of the silica particles. By means of in situ emulsion copolymerization of methyl methacrylate (MMA) and butyl acrylate (BA), a series of core–shell silica hybrid particles with nanometre poly(MMA-co-BA) shells were fabricated, which were subsequently compounded with isotactic polypropylene (PP) in the molten state. Upon increasing the feed silica:monomer ratio from 1:1 to 4:1, the poly(MMA-co-BA) shell thickness on the silica core decreased from 50 nm to 10 nm. Owing to the existence of the nanometre poly(MMA-co-BA) shells, the silica hybrid particles were monodispersed in the PP matrix, causing homogeneous debonding at the PP/silica interface, followed by plastic void expansion and matrix shear yielding during impact fracture. These deformation mechanisms greatly toughened the PP–silica composites. A critical shell thickness of poly(MMA-co-BA) was needed to achieve optimal mechanical properties. That is, when the polymer shell thickness was 15 nm, compared to pure PP, the impact toughness of the PP–silica composite was more than doubled with little degradation of tensile strength.
Recently, a sol–gel process combined with polymerization of monomers was used to fabricate polymer-based composites with uniform particle dispersion.28–31 Monodispersed core–shell silica particles covered with polymer chains were successfully synthesized.6,32–35 Sun et al.36 prepared PP–silica nanocomposites by in situ sol–gel reaction with the aid of carbon dioxide. To the best of our knowledge, there is no report on fabricating monodispersed polymer–sol–gel silica composites by melt compounding. Here, a series of core–shell silica hybrid particles with poly(MMA-co-BA) shells were synthesized through in situ emulsion copolymerization of MMA and BA, then melt compounded with isotatic PP to prepare PP–silica composites. The main goal of the present research was to study the effect of interface characteristics on the mechanical properties of PP–silica composites by adjusting the polymer shell thickness on the silica particles.
To introduce vinyl groups on the surface of the silica particles, 10 mL of γ-MPS was added to the above suspension and stirred for 24 h at ambient temperature. Three cycles of centrifugation and washing with ethanol were used to remove the excess γ-MPS. Then, the final vinylated silica particles were dried in a vacuum at low temperature for 12 h.
According to ref. 38, core–shell silica hybrid particles were prepared by in situ emulsion copolymerization. The feed ratios of the silica and comonomers were 1:0, 1:1, 2:1 and 4:1; the final silica hybrid particles were designated Si, Si-1, Si-2 and Si-3, respectively. 10 g vinylated silica particles, 0.25 g emulsifier (sodium dodecyl sulfate, SDS), 0.25 g sodium bicarbonate and 250 g deionized water were placed in a 500 mL four-necked flask with a mechanical stirrer (with a fixed stirring rate of 150 rpm), thermometer, condenser, in a nitrogen atmosphere and the flask was placed in a 40 kHz ultrasonic water bath. After the mixture was heated to 70 °C, the potassium persulfate (KPS) was divided into four equal parts by weight, and added into the flask in 0.75 h intervals. The mixture of MMA and BA (1:1 by weight) was added dropwise at a rate of 0.5 mL h−1. After 8 h, the mini-emulsion was centrifuged at 6000 rpm and washed with water and ethanol, respectively, for three cycles to remove SDS, unreacted monomer and free poly(MMA-co-BA) copolymer. Finally, the prepared silica hybrid particles were dried at 60 °C in a vacuum. Poly(MMA-co-BA) copolymers were also synthesized using the above procedure.
The morphologies of the PP–silica composites were observed using a JSM-5510 LV scanning electron microscope (Japan) on cryo-fractured specimens after immersion in liquid nitrogen. All the surfaces were coated with a thin layer of gold prior to SEM examination. Tensile tests were performed using an Instron 4206 machine at 20 °C with a crosshead speed of 50 mm min−1. Izod notched impact toughness was measured with a Ceast pendulum impact tester at 20 °C. The results reported here represent the average values from five samples. Dynamic mechanical analysis (DMA) was also conducted on a TA Q800 Instrument dynamic mechanical analyzer at a fixed frequency of 10 Hz and an oscillation amplitude of 0.15 mm. The temperature range studied was from −60 to 130 °C with a heating rate of 3 °C min−1. The crystallization and melting behaviors of PP and PP–silica composites were measured by DSC using a Perkin-Elmer DSC-7 instrument at a heating rate of 10 °C min−1 in dry nitrogen. All specimens were heated to 220 °C and kept at this temperature for 3 min before quenching to ambient temperature to eliminate previous thermal histories. For non-isothermal crystallization measurements, the samples were heated to and remained at 220 °C for 3 min, and then cooled at a rate of 10 °C min−1.
Scheme 1 |
Fig. 1 FTIR spectra of (a) pristine sol–gel silica, (b) vinylated silica, and (c) extracted hybrid particle. |
Also, the introduction of γ-MPS on the silica surface improves the hydrophobic properties of silica, which is beneficial for the formation of a stable emulsion with SDS. After being vinylated, the silica particles were further modified by in situ copolymerization of MMA and BA as shown in scheme 2.
Scheme 2 |
Clearly, there is a sharp CO stretching peak at 1731 cm−1 (see curve (c)), which indicates that poly(MMA-co-BA) copolymers are successfully grafted onto the silica particles.
Fig. 2 shows TGA curves for pristine sol–gel silica and hybrid particles. It can be seen that all have obvious weight losses (ca. 5 wt%) below 200 °C. Sertchook et al.39 and Ogawa et al.40 attributed this weight loss to the loss of absorbed water and dehydration of the residual silanol groups. To check these mechanisms, we studied the TGA behavior of pristine sol–gel silica where the temperature was increased to 200 °C, kept constant for 5 min, and cooled to ambient temperature. We found that the weight increased during cooling due to the adsorbed air but the values were slightly lower than during heating. So, we believe the weight loss seen in Fig. 2 is caused by the dehydration of residual silanol groups and release of absorbed water and air in the silica particles. Additionally, the pristine sol–gel silica particles are stable at high temperatures. Even at 800 °C the loss is only 9.2 wt%. However, silica hybrid particles have a sharp weight loss from 200 to 600 °C owing to the thermal oxidation and decomposition of the poly(MMA-co-BA) copolymers grafted onto the silica particles. Based on the residues at 800 °C, the grafting percentage values of poly(MMA-co-BA) on Si-1, Si-2 and Si-3 are 24.2, 16.8 and 12.3%, respectively. Hence, the grafted percentage of poly(MMA-co-BA) on silica decreases with increasing feed ratio of silica to comonomer.
Fig. 2 TGA curves for pristine silica (Si) and extracted hybrid particles (Si-1, Si-2, Si-3). |
Fig. 3 shows TEM images of pristine sol–gel silica and core–shell hybrid particles. Obviously, the average diameter of pristine sol–gel silica particles is ∼200 nm (see Fig. 3(a)). After the silica particles were modified by γ-MPS and in situ copolymerized with MMA and BA, these hybrid particles form a uniform monodispersed core–shell structure with one silica particle as the core and poly(MMA-co-BA) copolymers as the shell. For a feed ratio of silica to comonomer of 1:1, the poly(MMA-co-BA) shell on Si-1 is ∼50 nm thick (see Fig. 3(b)). With decreasing comonomer content, the poly(MMA-co-BA) shell thicknesses decrease to 15 and 10 nm for Si-2 and Si-3, respectively (see Figs. 3(c) and (d)). It is noted that the average molecular weight of poly(MMA-co-BA) attached to Si-1 and Si-2 is roughly 1–6 × 106 g mol−1 based on SEC, which indicates that the existence of silica does not affect the chain propagation during in situ copolymerization of MMA and BA.
Fig. 3 TEM images of pristine sol–gel silica and hybrid particles. (a) Si, (b) Si-1, (c) Si-2 and (d) Si-3 |
Samples | Tensile yield strength/MPa | Impact toughness/kJ m−2 |
---|---|---|
PP | 41.2 | 2.99 |
PP–Si | 41.7 | 2.91 |
PP–Si-1 | 36.7 | 5.01 |
PP–Si-2 | 40.0 | 6.14 |
PP–Si-3 | 39.5 | 5.45 |
PP–poly(MMA-co-BA) | 39.1 | 2.96 |
To understand the mechanical behavior of PP–Si-2, it is necessary to examine its structure compared with that of the PP–pristine sol–gel silica composite. Fig. 4 shows SEM images of impact-fractured PP–silica composites filled with pristine sol–gel silica, and Si-2. Obviously, the impact-fractured surface of the PP–Si-2 composite is rougher than that of the impact-fractured PP–Si composite (see Figs. 4(a) and (c)), which provides direct evidence that the toughness of the PP–Si-2 composite is higher than that of the PP–Si composite. Also, the pristine sol–gel silica (Si) particles are easily aggregated in the PP matrix (see Fig. 4(b)) due to the high surface energy of the Si particles, and the different surface properties of PP and Si. During impact fracture, the aggregated silica clusters are easily pulled out from the matrix. However, when the nanosilica particles are modified by γ-MPS, and followed with in situ copolymerization of MMA and BA, the poly(MMA-co-BA) shells on the silica cores serve as a compatibilizer enhancing the interaction between the PP matrix and the silica hybrid particles (Si-2), leading to uniform mono-dispersion of the Si-2 particles in PP and large interfacial areas with much improved PP–Si-2 adhesion. Comparing Fig. 4(d) to 4(b), debonding of the monodispersed Si-2 particles and the ensuing plastic void expansion of the PP matrix prevail at the fracture surface. These sites are marked with red circles. A predominant stress-whitened zone beneath the fracture surface of the PP–Si-2 composite owing to matrix shear yielding is also found. However, PP and PP–Si exhibit nil or negligible stress-whitened zones and hence have much lower toughness values compared to PP–Si-2 (see Table 1). Therefore, similar to the epoxy–nanosilica composites studied by Johnsen et al.,41 debonding of Si-1,-2,-3 particles, plastic void expansion and shear yielding of PP matrix are the major toughening mechanisms, resulting in the high impact toughness values obtained for PP–Si-1, PP–Si-2 and PP–Si-3 composites as shown in Table 1.
Fig. 4 SEM images of impact-fractured PP–silica composites. (a) Low- (×1000), and (b) high- (×10000) magnification images of composites filled with pristine sol–gel silica. (c) Low- (×1000), and (d) high- (×10000) magnification images of composites filled with Si-2. Red circles in (d) show typical PP/Si-2 interface debonding and plastic void expansion in the PP matrix. |
Fig. 5 shows the loss factor (tan δ) versus temperature for the PP, PP–Si and PP–Si-2 composites. It can be seen that the glass transition temperature (designated as Tg) of pure PP is 19.5 °C. The incorporation of sol–gel silica particles decreases Tg of PP phase in the PP–Si composite to 11.9 °C caused by the aggregation of silica particles.40 Generally, well-dispersed particles limit the mobility of polymer chain segments and increase the Tg of the matrix.42 But, the Tg of the PP phase in the PP–Si-2 composite is further decreased to 6.4 °C, even though the dispersion of Si particles in the PP–Si-2 composite is far better than that in the PP–Si composite. These results indicate that the poly(MMA-co-BA) shells on the Si-2 particles do not restrict the mobility of the PP chain segments. Instead, they plasticize the PP–silica composite and toughen the PP matrix.
Fig. 5 Variation of loss factor (tan δ) with temperature for PP, PP–Si and PP–Si-2 composites. |
Fig. 6 displays the cooling and melting DSC curves for the PP, PP–Si and PP–Si-2 composites. Their crystallization peak temperature (Tcp), melting peak temperature (Tmp) and melting enthalpy (ΔHm) were determined from the DSC thermograms and are listed in Table 2. Assuming the melting enthalpy of 100% crystalline PP is 237 J g−1,43 their degree of crystallinity (Xc) was also calculated and is shown in Table 2. Compared to pure PP, the pristine sol–gel silica particles act as nucleation sites to increase the Tcp of the PP phase in the PP–Si composite from 110.5 °C to 120.0 °C. The incorporation of well-dispersed Si-2 particles further increases the Tcp of the PP phase in the PP–Si-2 composite to 123.0 °C. However, addition of silica particles destroys the packing regularity of the PP chains during crystallization, leading to lower Tmp and Xc than those of pure PP.
Fig. 6 (a) Cooling and (b) heating DSC curves for the PP, PP–Si and PP–Si-2 composites. |
Finally, to examine the effect of the incorporation of pristine and surface-modified silica particles on the thermal stability of PP, Fig. 7 shows the TGA curves for the PP, PP–Si and PP–Si-2 composites. Their temperature of 5% weight loss (T5%) and residue values at 500 °C (W500) are listed in Table 2. Clearly, PP–Si and PP–Si-2 composites have the same thermal stability as pure PP. This means that the addition of pristine and modified silica particles does not affect the thermal stability of the PP matrix.
Fig. 7 TGA curves for PP, PP–Si and PP–Si-2 composites. |
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