Nanoscale highly filled epoxy nanocomposite

A new technique has been developed to prepare a highly filled epoxy-montmorillonite (MMT) nanocomposite using an organically modified MMT. Composites with clay content up to 70 wt.% exhibit unusual transparency, which is related to the spatial distribution of the mineral nanodomains. Dispersion of the layered silicate within the crosslinked epoxy matrix was verified using X-ray diffraction pattern, revealing layer spacings of 30 and 70 Å. Examination of these materials by scanning electron microscopy and transmission electron microscopy showed that intercalates have wholly layered morphology at all scales, oriented parallel to the surface of the specimen and have good wetting to the silicate surface by the epoxy matrix. Silicate lamellae intercalated with epoxy resin assembled into a cluster of about 50–120 nm thickness. These clusters assembled into superclusters with an average thickness of 300 nm. Studies by the Vickers hardness test of an epoxy-MMT nanocomposite containing 60 wt.% MMT indicated that the diamond pyramid hardness was 10–29 kg/mm2.