Silica hybrid particles with nanometre polymer shells and their influence on the toughening of polypropylene

Abstract

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.