The importance of specific mechanical energy during twin screw extrusion of organoclay based polypropylene nanocomposites

This study demonstrates how the specific mechanical energy (SME) can be used to describe the influence of extrusion parameters such as screw rotation speed, feed rate and barrel temperature on clay dispersion in organoclay (OMMT) based polypropylene nanocomposites. These materials were prepared by a melt mixing masterbatch process via twin screw extrusion with a wide range of processing conditions. Maleated polypropylene (PP-g-MA) was used as a compatibilizer to allow clay exfoliation. Characterization of the morphological evolution along the extrusion profile revealed that microscale dispersion primarily happens in the melting zone, whereas continuous exfoliation is observed all along the kneading zones, up to the die exit. The results indicate that exfoliation in the kneading zones is mainly issued from clay tactoids and small aggregates with characteristic size inferior to 10 μm, emphasizing the crucial role of primary microscale dispersion on the final structure and properties of the nanocomposites. Relevant quantitative prediction of the multiscale dispersion state along the extrusion profile was obtained using the melt state SME as unique parameter.