Polymer Nanocomposites: April 2007
Polymer Nanocomposites: April 2007
Polymer Nanocomposites: April 2007
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Polymer Nanocomposites
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Nanocomposites
of this rapidly evolving research and de-
velopment enterprise.
The numerous reports of large prop-
erty changes with very small additions of
nanoparticles (⬍1–5 wt%) have fueled the
Karen I. Winey and Richard A. Vaia, view that nanoparticles are a magic pixie
dust that delivers huge dividends. In fact,
Guest Editors recent market surveys have estimated
global consumption of polymer nanocom-
posites at tens of millions of pounds
Abstract (⬃$250 million), with a potential annual
Polymer nanocomposites (PNCs)—that is, nanoparticles (spheres, rods, plates) average growth rate of 24%, to almost
dispersed in a polymer matrix—have garnered substantial academic and industrial in- 100 million pounds in 2011 at a value
terest since their inception, circa 1990. This is due in large part to the incredible promise
exceeding $500–800 million.7–9 Major rev-
enues are forecast from large commercial
demonstrated by these early efforts: PNCs will not only expand the performance space
opportunities such as automobile parts,
of traditional filled polymers, but introduce completely new combinations of properties
coatings, flame retardants, and packaging,
and thus enable new applications for plastics. Low volume additions (1–5%) of nanopar-
where lower-cost, higher-performance
ticles, such as layered silicates or carbon nanotubes, provide property enhancements materials would improve durability and
with respect to the neat resin that are comparable to those achieved by conventional design flexibility while lowering unit price
loadings (15–40%) of traditional fillers. The lower loadings facilitate processing and re- and life cycle cost.
duce component weight. Most important, though, is the unique value-added properties Whatever the case for the long-term
not normally possible with traditional fillers, such as reduced permeability, optical economic growth of polymer nanocom-
clarity, self-passivation, and increased resistance to oxidation and ablation. These posites, the opportunities to deliver targeted
characteristics have been transformed into numerous commercial successes, including material performance reside with the im-
automotive parts, coatings, and flame retardants. This issue of the MRS Bulletin provides plications associated with nanoscale multi-
a snapshot of these exemplary successes, future opportunities, and the critical scientific phase systems. There are important
challenges still to be addressed for these nanoscale multiphase systems. In addition, differences when the fillers shrink from
these articles provide a perspective on the current status and future directions of microscale to nanoscale. This issue of the
polymer nanocomposite science and technology and their potential to move beyond MRS Bulletin provides a snapshot of exem-
additive concepts to designed materials and devices with prescribed nanoscale plary successes, future opportunities, and
composition and morphology. the critical scientific challenges still to be
addressed for these nanoscale multiphase
systems. In addition, these articles provide
a perspective on the current status of poly-
mer nanocomposite science and technol-
Introduction ogy as well as future directions to move
Polymers have been a part of life since expensive engineering plastic. Similarly, it beyond additive concepts to designed
the beginning of humankind. From tar and combining different polymers to form a materials and devices with prescribed
shellac, tortoise shell and horns, to today’s polymer blend or resin can increase the nanoscale composition and morphology.
synthetic offerings such as polyolefins, value of existing polymers.
epoxies, and engineering resins, polymers Polymer nanocomposites incorporate a The Nano Advantage
provide crucial materials for construction, new spectrum of fillers that extend the When fillers are nanoscopic, there are
commerce, transportation, and entertain- function and utility of polymers while advantages afforded to filled polymers and
ment across the globe. Estimates of global maintaining the manufacturing and proc- composites that lead to performance en-
polymer production range from 250 billion essing flexibility inherent to plastics, ther- hancements. These advantages result pri-
pounds to more than 400 billion pounds mosets, and resins. In particular, polymer marily from filler size reduction and the
(approximately 114–181 billion kg) annually. nanocomposites have been successful concomitant increase in surface area. The
In the majority of their diverse applica- with regard to overcoming traditionally size of the additive might drop by up to
tions, polymeric materials are not chemi- antagonistic combinations of properties. three orders of magnitude relative to con-
cally or molecularly homogenous but are Since the first reports in the late 1980s,1–6 ventional alternatives. In contrast, many
multicomponent systems. By adding fillers, the term “polymer nanocomposite” has nanotechnologies associated with electri-
such as minerals, ceramics, metals, or even evolved to refer to a multicomponent sys- cal or optical properties benefit from new
air, materials scientists can generate an infi- tem in which the major constituent is a physical phenomena arising from quan-
nite variety of materials with unique phys- polymer or blend thereof and the minor tum confinement effects induced by the
ical properties and competitive production constituent has at least one dimension below nanoscale dimensions of the material. The
costs. For example, adding filler to a com- 100 nm. Polymer nanocomposite is an ap- literature about polymer nanocomposites
modity thermoplastic such as polypropy- propriate synonym for inorganic–organic contains many discussions about the im-
lene can achieve performance levels that hybrids and molecular composites and also plications and physical manifestations of
would otherwise require a much more encompasses mature commercial products the reduction in filler length scale.10–14
Traditional Fillers
Carbon black32 agglomerate 10–100 1–5 … 10–100 0.1–0.4 tires, hoses, shoes, elastomers
of spheres
Carbon fiber33 rods 5,000–20,000 10–50 300–800 0.1–10 100–1000 aerospace, automotive, marine,
Polymer Nanocomposites
sporting, medical
Carbon graphite34 plate 250–500 15–50 500–600 1–10 100–500 gaskets, seals
35
E-glass rod 10,000– 20–30 75 … … marine, automotive,
20,000 construction, filtration
Mineral: silica37,38 agglomerate 8,000–30,000 5–10 30–200 … 1–10 reinforced plastics, thermal
of spheres insulator, paint, rubber reinforcing
agent
Mineral: talc, china platelet 5,000–20,000 5–10 1–70 … 1–10 paper, consumer goods,
clay37,39 construction
Nanoscale Fillers
Carbon nanofiber40 rod 50–100 50–200 500 700–1000 10–20 hoses, aerospace, ESD/EMI
shielding, adhesives
Carbon MWNT41 rod 5–50 100–10,000 1,000 500–10,000 100–1000 automotive, sporting, ESD/EMI
shielding
Carbon SWNT42 rod 0.6–1.8 100–10,000 1,500 1000–10,000 1000 filters, ESD/EMI shielding
Nano-Al2O337,45 sphere 300 ~1 50 10–14 20–30 seal rings, furnace liner tubes,
gas laser tubs, wear pads
a
Dispersible unit.
b
Aspect ratio is defined as the long axis to short axis irrespective of shape. Note that this differs from Figure 1.
ESD is electrostatic discharge; EMI is electromagnetic interference; MWNT is multiwall carbon nanotube; SWNT is single-wall carbon nanotube.
Future Outlook and piezoresistive materials for MEMs- 12. A. Bansal, H. Yang, C. Li, K. Cho, B.C.
What’s next? Where are the ground- based sensors. In addition, new proc- Benicewicz, S.K. Kumar, L.S. Schadler, Nature
breaking opportunities? What are the essing tools and on-line controls are being Materials 4, 693 (2005).
developed to either (1) uniformly distrib- 13. R. Krishnamoorti, R.A. Vaia, E.P. Giannelis,
challenges that pervade polymer nano- Chem. Mater. 9, 1728 (1996).
composites? Of extreme importance in all ute nanofiller to produce homogeneous
14. F.W. Starr, T.B. Schroeder, S.C. Glotzer,
the potential markets is the establishment bulk properties or (2) spatially vary the Macromolecules 35, 4481 (2002).
of a better, quantitative understanding of nanofiller concentration to meet specific 15. SciFinder, Chemical Abstract Service (CAS)
the occupational health risks.31 For poly- design criteria. One might refer to these of the American Chemical Society, CAPLUS
mer nanocomposites, this is particularly two classes of polymer nanocomposites and MEDLINE databases, October 8, 2006. Data
important during the production of nano- as nano-“filled” systems and nano- resulted from a keyword search on “nanocom-
sized fillers and composite fabrication, as “composite” systems, respectively. By posite” and selecting citations that included this
well as during recycling, incineration, or drawing inspiration from biology and en- concept (25,435 total citations). Results were re-
gineered fiber-reinforced composites, fined using “polymer” (10,350 total citations),
combustion.
“nanotube or nanorod” (864 total citations), or
Whereas the recent increased availabil- polymer nanocomposites with spatially
“clay or (layered silicate) or montmorillonite”
ity of the new nanoscale fillers has been a controlled morphology are beginning to (3,938 total citations). Other keyword combina-
major contributor to the rapid develop- provide viable options to critical compo- tions did not drastically modify the refined
ment of polymer nanocomposites, robust nents of active devices, such as fuel cell number of citations (⬍2–3%).
structure–property–processing relation- membranes, batteries, photovoltaics, sen- 16. E.P. Giannelis, Adv. Mater. 8, 29 (1996).
ships are critical to further market infiltra- sors, and actuators. 17. M. Alexandre, P. Dubois, Mater. Sci. Eng., R
tion. Relationships that provide a priori Polymer nanocomposites have recently 28, 1 (2000).
predictions of macroscopic properties for become part of established modern tech- 18. S.S. Ray, M. Okamoto, Prog. Polym. Sci. 2,
a given polymer, a specific nanoscale filler nologies, but the most significant accom- 1539 (2003).
plishments of these materials are still 19. M. Okamoto, “Polymer/Clay Nanocom-
(or fillers), and a particular spatial arrange- posites,” in Encyclopedia of Nanoscience and
ment of the filler are still in their infancy. ahead of us. As an increasing number of Nanotechnology, H.S. Nalwa, Ed. (American
For example, to what extent can existing scientists and engineers contribute to the Scientific, Stevenson Ranch, CA, 2004), vol. 8, p. 1.
continuum composite theories be modi- understanding of polymer nanocompos- 20. E.T. Thostenson, C. Li, T.-W. Chou, Compos.
fied to account for the implications that ites, what remains to be seen is which Sci. Technol. 65, 491 (2005).
arise when the filler is comparable to the products will be critically enhanced and 21. L.F. Drummy, H. Koerner, B.L. Farmer, R.A.
polymer in size? Are the properties cur- enabled by this broad and evolving class Vaia, Advanced Morphology Characterization of
rently being achieved in polymer nanocom- of materials. Clay-Based Polymer Nanocomposites: CMS Work-
posites as high as we can expect to obtain? shop Lecture Series (Clay Minerals Society,
Chantilly, VA, 2006) vol. 14.
However, approaches to these chal- Acknowledgments 22. S.C. Tjong, Mater. Sci. Eng., R 53, 73
lenges are not without precedent. The The authors thank Minfang Mu (Uni- (2006).
underlying science and constitutive rela- versity of Pennsylvania) for compiling the 23. F. Hussain, M. Hojjati, M. Okamoto, R.E.
tionships for these nanoscopic materials data for Table I. K.I. Winey thanks Dupont Gorga, J. Compos. Mater. 40, 1511 (2006).
should share commonality with collections for hosting her sabbatical visit and acknowl- 24. X.-L. Xie, Y.-W. Maia, X.-P. Zhou, Mater. Sci.
of nanoscopic polymer chains, whose frame- edges funding from NSF-DMR-MRSEC- Eng., R 49, 89 (2005).
work has been developed through nearly 05–20020. R.A. Vaia thanks the Materials 25. M. Moniruzzaman, K.I. Winey, Macromole-
a century of chemistry and physics and is cules (Review) 39, 5194 (2006).
Research Laboratory at the University of
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Karen I. Winey Richard A. Vaia Jeff Baur Brian C. Benicewicz Shane E. Harton
Karen I. Winey, Guest NSF Young Investigator NanoMaterials Strategy Outstanding Engineers Jeff Baur is a senior re-
Editor for this issue of Award in 1994 and was Group and chair of the and Scientists Award search engineer for the
MRS Bulletin, is a pro- elected fellow of the NanoScience and Tech- (2006) from the Affiliate Advanced Composites
fessor of materials sci- American Physical Soci- nology (NST) Strategic Societies Council of Branch within the Air
ence and engineering at ety in 2003. Winey is Technology Team at the Dayton, Ohio. Vaia Force Research Labora-
the University of Penn- currently chair of the U.S. Air Force Research serves on the editorial tory’s Materials and
sylvania. She earned her Polymer Physics Gordon Laboratory (AFRL). He boards of Chemistry of Manufacturing Direc-
BS degree in materials Research Conference received his PhD degree Materials, Macromole- torate. His received his
science and engineering scheduled for 2010. She in materials science and cules, and Materials PhD degree from the
from Cornell University recently published an engineering at Cornell Today. He is on the MRS Massachusetts Institute
and her MS and PhD invited review article University in 1995 and board of directors, and of Technology’s pro-
degrees in polymer sci- entitled “Polymer was a distinguished is a member-at-large for gram in polymer science
ence and engineering Nanocomposites graduate from Cornell’s the Division of Poly- and technology in 1997.
from the University of Containing Carbon Air Force ROTC. meric Materials Science Baur has held re-
Massachusetts under the Nanotubes” in Vaia’s research group and Engineering of the search and management
direction of Edwin L. Macromolecules (39, focuses on polymer American Chemical So- positions within the Air
Thomas. 5194–5205, 2006). nanocomposites, pho- ciety. He has authored Force Research Lab,
Winey probes Winey can be reached tonic technologies, and more than 100 papers Borden Chemical UV
structure–property at 3231 Walnut St., Uni- their impact on develop- and patents. Coating Division, and at
relationships in versity of Pennsylvania, ing adaptive soft matter. Vaia can be reached at MIT’s Institute for Sol-
nanotube–polymer com- Philadelphia, PA His honors and awards the Air Force Research dier Nanotechnologies,
posites, ion-containing 19104-6272, USA; tel. include Air Force Out- Laboratory, 2941 and has published nu-
polymers, and block 215-898-0593, fax standing Scientist (2002); Hobson Way, Bldg. 654, merous papers in ad-
copolymers, where the 215-573-2128, and e-mail MRL Visiting Professor Wright-Patterson Air vanced electrical,
properties of interest in- [email protected]. at the University of Cali- Force Base, OH optical, and mechanical
clude electrical fornia, Santa Barbara 45433-7750 USA; tel. properties of polymer
conductivity, thermal Richard A. Vaia, (2006); Air Force Office 937-255-9184, fax composites. His current
conductivity, mechanical Guest Editor for this of Scientific Research 937-255-9157, and interests are in nanocom-
properties and perme- issue of MRS Bulletin, Star Team (2003–2005, e-mail richard.vaia@ posites for improvement
ability. She received an is the lead of the 2005–2007), and the wpafb.af.mil. of fiber-reinforced
dean for research in phenomena, nanotech- Pennsylvania. She re- has served as editor of also serves as associate
2005. His primary nology, and polymers. ceived her BSc degree in Industrial and Engineer- editor for North Amer-
research area is in the Kumar can be reached chemistry and her MSc ing Chemistry Research, ica of Soft Matter, a new
understanding of at the Department of degree in the Depart- published by the Ameri- interdisciplinary journal
structure–processing– Chemical Engineering, ment of Macromolecular can Chemical Society, from the Royal Society
property relations for Columbia University, Science at Fudan Uni- since 1986. of Chemistry.
multicomponent poly- 500 W. 120th St., New versity, China. At Fudan Paul can be reached Pochan can be
meric materials, with re- York, NY 10027 USA; University, Mu worked at the Department of reached by e-mail at
cent extensions into tel. 212-854-2193, fax with Ming Jiang on Chemical Engineering, [email protected].
biomaterials for drug 212-854-3054, and e-mail self-assembly of University of Texas
delivery and the devel- sk2794@ protein-graft-dextran at Austin, Austin, Linda S. Schadler is a
opment of high- columbia.edu. and polymer complexes. TX 78712 USA; tel. professor in materials
performance ceramic Currently, she is work- 512-471-5392, fax science and engineering
materials. Sarah L. Lewis is pursu- ing on the diffusion be- 512-471-0542; and e-mail at Rensselaer Polytech-
Krishnamoorti can be ing her PhD degree in havior of polymers into [email protected]. nic Institute. She gradu-
reached at the Depart- materials science and carbon nanotube/ ated from Cornell
ment of Chemical Engi- engineering at Rensse- polymer nanocompos- Darrin J. Pochan is an University in 1985 with
neering, University of laer Polytechnic Institute ites, as well as the associate professor in a BS degree in materials
Houston, 4800 Calhoun in Troy, N.Y. She re- preparation and charac- the Materials Science science and engineering
Rd., Houston, TX ceived her MS degree in terization of composites and Engineering De- and received a PhD de-
77204-4004 USA; tel. materials science and with cellular nanotube partment and the gree in materials science
713-743-4312, fax engineering from networks. Delaware Biotechnology and engineering in 1990
713-743-4323, and e-mail Lehigh University in Mu can be reached at Institute at the Univer- from the University of
[email protected]. 2003 and her BSc degree the University of Penn- sity of Delaware. He Pennsylvania. Schadler
in biomedical materials sylvania, 3231 Walnut joined the department in joined Rensselaer
Sanat K. Kumar is a science from the Univer- St., Philadelphia, PA 1999 after earning his in 1996.
professor in the Chemi- sity of Manchester 19104-6272, USA; tel. PhD degree in polymer She is a current mem-
cal Engineering Depart- Institute of Science 215-898-2700 and science and engineering ber of the National Ma-
ment at Columbia and Technology in 2001. e-mail minfang@ at the University of terials Advisory Board,
University. He received Her research interests seas.upenn.edu. Massachusetts Amherst and in addition to her
his BS degree from the are in controlling and and having an NRC research focus on inter-
Indian Institute of predicting properties Donald R. Paul holds postdoctoral fellowship faces in nanocomposites,
Technology, Madras, in polymer the Ernest Cockrell Sr. at the National Institute she is the education and
in 1981 and his PhD nanocomposites. Chair in Engineering at of Standards and outreach coordinator for
degree from the Lewis can be reached the University of Texas Technology. the NSF-funded Center
Massachusetts Institute at the Department of at Austin and also is the At the University of for Directed Assembly
of Technology in 1987. Materials Science and director of the Texas Delaware, Pochan has of Nanostructures,
Kumar has held faculty Engineering, Rensselaer Materials Institute. He developed a research headquartered at Rens-
positions at the Pennsyl- Polytechnic Institute, joined the Department program around the selaer.
vania State University 110 Eighth St., Troy, NY of Chemical Engineering construction of new ma- Schadler can be
and Rensselaer Poly- 12180 USA; tel. at UT in 1967. Paul’s re- terials and nanostruc- reached at the Depart-
technic Institute. 518-276-3011, fax search interests include tures via molecular ment of Materials
His research focuses 518-276-8554, and e-mail polymer blends, mem- self-assembly mecha- Science and Engineer-
on synthetic and bio [email protected]. branes, processing, and nisms. His recent honors ing, Rensselaer
polymers, nanocompos- nanocomposites. He include an NSF Career Polytechnic Institute,
ites, and nanomaterials. Minfang Mu is a PhD was elected to the Na- Award, the DuPont 110 Eighth St., Troy, NY
His work impacts the degree candidate in the tional Academy of Engi- Young Faculty Award, 12180 USA; tel.
fields of biochemical Department of Materials neering in 1988 and to and the Dillon Medal 518-276-2022, fax
engineering, composite Science and Engineering the Mexican Academy of from the American 518-276-8554, and e-mail
materials, interfacial at the University of Sciences in 2000, and Physical Society. Pochan [email protected].