Polymer Nanocomposite : An Advanced New Material for

Plastic and Textile Applications

A K Ghosh, Mangala Joshi

A K Ghosh, Centre for Polymer Science and Engineering

Expertise in Rheology and Processing of Polymers, Reactive Processing, Polymer Blends and
Alloys, Mixing and compounding, Polymer Reaction Engineering, Nanocomposites, Computer
Aided Modelling and Simulation. akghosh@polymers.iitd.ernet.in

Mangala Joshi, Department of Textile Technology

Expertise in Nanotechnology Applications in Textiles, Polymer Nanocomposite fibers and
coatings, Nano-Biomaterials, Bioactive & Functional Textiles, Environmental Friendly
Technologies for Textiles using a blend of herbal and nano materials.
mangala@textile.iitd.ernet.in

electronics etc. The focus is to disperse nanofillers

P
olymer nanocomposites are a unique new
class of materials with an ultrafine dispersion
of nanomaterials in a polymeric matrix. They
have recently gained a great deal of attention because
of the much superior properties in terms of increased
strength and modulus, improved heat resistance,
decreased gas permeability and flame retardance at
very low loadings of < 5-wt% of nanofillers. With these
improved set of properties, they show a lot of promise
in developing a range of advanced plastic and textile
products. The plastic applications can be in domains
such as biomedical, electronics, energy, automotive,
sports gear, packaging and also aircraft and aerospace
engineering. The textile applications include potential
areas such as- nanocomposite fibers, nanofibers
and other nanomaterial incorporated fibers and
coated textiles for applications in medical, defense,
aerospace and other technical textile applications
such as filtration, protective clothing besides a range
of smart and intelligent textiles. At Centre for Polymer
Science and Engineering and Textile Technology
Department, IIT Delhi, our research group is actively
involved in the research and development activities
focused in the area of polymer nanocomposites.
Development of Nanocomposites
Innovative composites and nanocomposites are
significantly widening the range of applications of
thermoplastics as well as thermosets in areas such
as packaging, automotive, bio-medical devices,
in polymer matrix and study its effect on mechanical
properties and rheological behaviour. Polymers like
polyolefin, polyamides, polystyrene, ethylene-octene
copolymers have been studied with various nanofillers
like nanoclay, nanotalc, carbon nanotubes and carbon
nanofibers.
In an ongoing project, sponsored by DST, a
state of the art facility for processing of polymer
nanocomposites by melt intercalation route has
been set up. It includes an advanced twin screw
extruder with a modular design and integrated with
specially designed sensors such as dielectric and
fluorescence which can monitor online the dispersion
of nanofillers such as nanoclays in the polymer
matrix. Since, achieving the nanolevel dispersion of
nanomaterials is the most crucial step in achieving
the right morphology, structure and properties in
any nanocomposite, this facility is very important
and a large number of projects are currently being
undertaken on various systems. The morphology
of the layered silicate based nanocomposite is
very complex and may include microparticles,
tactoids, and individual layers. Many of the desirable
properties of these polymer nanocomposites are
related to the quality of the dispersion, including
polymer intercalation into the clay galleries and/or
exfoliation (delamination) into individual clay platelets.
In intercalated nanocomposites, the insertion of a
polymer matrix into the layered silicate structure occurs
in a crystallographically regular fashion, regardless of

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the clay to polymer ratio. Intercalated nanocomposites
are normally interlayered by a few molecular layers of
polymer. Conceptually flocculated nanocomposites
are same as intercalated nanocomposites. However,
silicate layers are some times flocculated due to
hydroxylated edge–edge interaction of the silicate
layers. In an exfoliated nanocomposite, the individual
clay layers are separated in a continuous polymer
matrix by an average distance that depends on the
clay loading. Usually, the clay content of an exfoliated
nanocomposite is much lower than that of an
intercalated nanocomposite (Fig.1).

Figure 1: Morphology development in polymer nanocomposites.

Transmission electron microscopy (TEM) provides a qualitative local structural characterization

(Figs. 2 and 3). As a result, an extensive imaging is required to ensure a representative view of the whole
material.

Figure 2: TEM micrographs of PP/clay nanocomposites developed at different time of mixing

(a) 4min (b) 8 min (c) 12 min

Figure 3: TEM micrographs of PP/clay nanocomposites developed with different Values of MFI
(a) 2 (b) 11 (c) 35

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 A range of new applications have been developed modifies the thermal degradation behaviour of HDPE
for polymer nanocomposites including non-halogen and also acts as a lubricating agent thus facilitating its
polymeric materials for aerospace industry to films drawing. The HDPE-POSS nanocomposite filaments
for packaging applications. Biodegradable polyolefins exhibit better UV resistance than neat HDPE filaments,
have been developed which degrade when exposed which may be attributed to the scattering/reflective
to microbial, enzymatic or other biological action into action of POSS.
CO2, water and simpler compounds or by the enzymatic
Bioactive nanocomposite fibers based on
action of microorganisms such as bacteria, fungi, and
antimicrobial nanomaterials are under development
algae. Processing of clay based nanocomposites of
under a sponsored project from USA Multinational
biodegradable polymers like polyhydroxylalkanoates
M/s. Lockheed Martin Corporation.
(PHA), polyester such as polycaprolactone (PCL),
poly (lactic acid) (PLA) and polyvinyl alcohol (PVA)
Nanocomposite Coatings
has also been studied.
Novel Polyurethane/ MMT (clay) based
nanocomposites as coatings for inflatables has been
Nanocomposite Fibers
explored in an ongoing sponsored research project
Polymers nanocomposites offer tremendous
from Defense R&D organization i.e. ADRDE Agra.
potential when produced in fiber form and offer
The coated fabrics showed improved gas barrier
properties that leapfrog those of currently known
property without affecting the transparency and tear
commodity synthetic fibres. We have investigated
strength.
nanocomposite fibers based on all the three major
types of nanofillers viz layered silicate nanoclays
(MMT), carbon nanotubes (CNT) and nanofibers, and
hybrid nanostructured materials such as POSS.
Compatibilized polypropylene (PP)/nanoclay
composite filaments were produced by melt
intercalation route. PP nanocomposite fibers showed
a significant improvement in tensile properties (70%
increase in tensile modulus and 40% increase in tensile
strength), an order increase in dynamic mechanical
(a) (Mag. X 50,000) (b) (Mag. X 4,235)
properties and much improved creep resistance over
neat PP filaments. The nanocomposite filaments Figure 4. SEM micrographs (a) Chitosan nanoparticles
could be dyed with disperse dyes unlike the neat PP (b) Nanoparticle coated cotton
filaments which are very difficult to dye.
Another interesting work is where nanoparticles
Another significant development is polyurethane such as nanosilica and nanoclay (kaolin) have been
(PU) nanocomposite fibers produced using solution coated on the cotton textile substrate to impart
intercalation technique. The developed fibers have superhydrophobicity and self-cleaning properties.
not only improved strength and modulus but also Self-assembled nanocoatings on textile using layer-by-
have better dyeability, weatherability and antitack layer (l-b-l) technique is under investigation, whereby
properties. This has been achieved through right various charged nanoparticles are being coated on
selection of organomodified inorganic nanofiller and cotton substrate along with a suitable polyelectrolyte
right processing technique to achieve uniform and using l-b-l technique to impart functionality like
homogeneous dispersion of clay in PU matrix. antimicrobial property (Fig. 4(a) & 4(b)).
Another development is high performance fibers
based on a novel class of hybrid nanostructured
filler, Polyhedral Oligomeric Silsesquioxane (POSS).
Incorporation of POSS at very low content < 0.5%

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Research Highlights

Publications
• S. Banerjee, M. Joshi and A. K. Ghosh ‘A spectroscopic approach for structural characterization of polypropylene/clay
nanocomposites’, Polymer Composites (Accepted), (2010).
• Sangita Nandi and Anup K Ghosh,‘Thermal, Mechanical and Electrical properties of chemically modified carbon nanofiber
filled polypropylene composites’, Polymer Engineering & Science, (2009), (in press).
• Sangita Nandi, Rajan K. Kamat and Anup K Ghosh, ‘Processability and thermal characteristics of polypropylene/carbon
nanofiber composites’, International Journal of Plastics Technology, 11, (2007), 763-774.
• Sangita Nandi, Anup K Ghosh, ‘Crystalization kinetics of impact modified polypropylene’, Journal of Polymer Research, 14,
1, (2007),387-396.
• Mayank Dwivedi, Anup K Ghosh, ‘Continuous fiber composites with nanoreinforced matrix: advanced structural materils’,
Polymer Plastics Technology and Engineering, 47,( 2008), 1147-1152.
• S Rana, R Alagirusamy and M Joshi, A Review on carbon epoxy nanocomposites, Journal of Reinforced Plastics and
Composites,28(4)(2009)461-487.
• Satpal Singh, Anup K. Ghosh, S. N. Maiti, Rahul Gupta and S.N. Bhattacharya ‘Poly (L-lactic acid)/Layered Silicate
Nanocomposite Blown Film for Packaging Application: Thermal, Mechanical and Barrier Properties’, Special Issue of
Journal of Polymer Engineering, accepted (In Press), (2010).
• M Joshi, A Bhattacharya and S Wazed Ali , Characterization Techniques for Nanotechnology Applications in Textiles, Indian
Journal of Fiber and Textile Research, September 2008,pp 304-317.
• Shikha Jain, Anup K Ghosh and Bhawna Kulshreshtha, ‘Processing and Properties of Polyethylene Based Nanocomposite
Films with Antimicrobial Activity’- International Journal of Plastics Technology, Vol 12, (2008), 943-955.
• M Joshi and B S Butola, Isothermal crystallisation of HDPE/POSS Nanocomposite: Effect of POSS as Nanofiller, J Appl
Polym Sci.,105(2),(2007) 978-985.
• M. Joshi and Viswanathan V, High Performance Filaments from compatibilised PP/clay nanocomposites, J of Appl Polym
Sci., 102(3), (2006), 2164.
• M. Joshi, Butola B S, Simon G and Kukalevab N, Rheological and viscoelastic behaviour of HDPE/ Octa methyl POSS
nanocomposites, Macromolecules, 39, (2006),1839.
• M. Joshi Banerjee K, Prasanth R and Thakare V, Polymer-Clay Nanocomposite based Coatings For Enhanced Gas Barrier
Property, Indian Journal of Fiber and Textile Research, (2006), 202.
• P. Santhana Gopala Krishnan, Mangala Joshi, Prachur Bhargava, Suresh Valiyaveettil, and Chaobin He, Effect of
Heterocyclic Based Organoclays on the Properties of Polyimide-Clay Nanocomposite, Journal of Nanosci. Nanotech,. 5,
(2005), 1136-1145.
• M. Joshi, M. Shaw and B. S. Butola, Studies on Composite Filaments from Nanoclay Reinforced Polypropylene, Fibers
and Polymers, 5(1),(2004), 1-9.
• M. Joshi and B. S. Butola, Studies on Nonisothermal Crystallization of HDPE / POSS Nanocomposites, M. Joshi and B. S.
Butola, Polymer, 45, (2004) 4953-4968.
• M. Joshi and B. S. Butola, Polymeric Nanocomposites - Polyhedral Oligomeric Silsesquioxanes (POSS) as Hybrid
Nanofiller, Journal of Macromolecular Science C-Polymer reviews,44(4)(2004) 389-410.

Research Projects
• “Intelligent processing of advanced polymeric materials”, Sponsored by DST, New Delhi
• Design and development of advanced composites “hinge joint”, Sponsored by Naval Research Board, New Delhi.
• Development of biodegradable plastic composite scaffolds for bone growth through microcellular injection moulding,
Sponsored by DBT, New Delhi.
• Development of Bioactive Nanocomposite Fibers, Sponsored by Lockheed Martin Corporation, USA
• Development of Polyurethane/clay nanocomposite based coated textiles and laminates for Inflatables, ADRDE, DRDO,
Agra.
• Developmnent of Nanomaterial enhanced High Performance coated Textiles, DST (Nano - Mission), New Delhi.
• High Performance Composite Filaments from Nanoclay Reinforced Polymers, MHRD, Govt. of India, New Delhi.
• Feasibility Study on development of polymer nanocomposite based Polyurethane coated fabrics, ADRDE, DRDO, Agra.

Research Scholars
• G V Raghunath Reddy, Roli Purwar, Sohel Rana, S Wazed Ali, Amitava Bhattacharya, Saikat Banerjee, Satpal Singh,
Manas Kashyap

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