Investigation into the Reprocessability of Polycarbonate/Organoclay Nanocomposites

With the rapid expansion in the use of nanomaterials, ensuring their reprocessability has become a critical consideration for the sustainable development of polymer-based nanocomposites. In this study, the effects of repetitive thermo-mechanical processing cycles on the properties of polycarbonate (PC)/organoclay nanocomposites, as well as the impact of reactive extrusion of reprocessed PC/organoclay nanocomposites using a chain extender, were investigated for the first time. The nanocomposites were processed three times using a twin-screw extruder, and a multi-anhydride functional chain extender was incorporated to counteract the thermo-mechanical degradation observed after the third extrusion cycle. Morphological analysis indicated that the delamination of clay nanolayers within the polymer matrix was slightly enhanced with increasing extrusion cycles, while the addition of the chain extender further promoted nanoclay exfoliation. Despite the improved clay dispersion in PC, both rheological and tensile measurements revealed the detrimental effects of repeated reprocessing on the nanocomposites. The chain extender effectively mitigated this degradation by relinking cleaved polymer chains; consequently, the complex viscosity and storage modulus at 0.1 Hz of the three-times-extruded nanocomposite increased by 248% and 426%, respectively, following chain extender incorporation. The effectiveness of the chain extender was further evidenced by a 27% enhancement in tensile strength. The glass transition temperatures of the samples were not significantly affected by either the extrusion cycles or the addition of the chain extender. The thermal stability of the nanocomposites decreased with increasing numbers of extrusion cycles; however, the incorporation of the chain extender imparted enhanced resistance to thermal degradation, as confirmed by thermogravimetric analysis.