Mill processing and properties of rubber–clay nanocomposites

The dispersion of nanoscale composites in elastomers, which generally have higher molecular weight and viscosity as compared to plastics, is a challenge. Several techniques have been proposed for improvement of the dispersion of nanofillers in the polymers [1]. For example, the interaction of natural layered silicates can be improved by ion-exchange of hydrated cation with organic cations such as introducing bulky alkylammoniums to obtain larger interlayer spacing and provide the galleries for the polymer chain diffusion. The resultant swollen nanoclay was dried and dispersed in the polymer matrix by means of high shear mixers [2–3]. In this paper we describe the results from a new method of incorporating nanofillers into solid rubber by use of a conventional two-roll mill, which we call the modified mill method. The properties of the resultant material are compared with that of the material prepared by a latex method. We also test processability parameters, tensile behavior and crosslink density of carbon black composites prepared by the same two methods to provide a comparison between the nanocomposites. The rubber–clay nanocomposites prepared by the mill method are shown to have a fine dispersed phase structure and good reinforcement properties.