Process Economics Program Report 51C
Published: June 2002
With the rush of interest in all things related to nanotechnology,
polymer nanocomposites represent one of the emerging spin-offs of this exciting
new technology. The push in nanocomposites is occurring worldwide with a large
number of corporations and research institutions studying potential applications.
Polymer nanocomposites are polymer either thermoset or thermoplastic reinforced
with a small quantity (<10%) of nanometer-size particles. Nanocomposites
offer new and improved properties compare to conventional plastics due to the
interaction of nanoparticles on a nanometer scale with the polymer phase and
the high aspect ratio of the nanoparticles. Because of the new product properties,
the growth in polymer nanocomposite demand is expected to be strong with nanocomposites
replacing existing conventional composites and higher performance products.
In 1987, Toyota Central R&D disclosed a nanocomposite composition consisting
of nylon 6 and nanoparticles of organically modified montmorillonite clay. Ube,
Unitika, Honeywell and Bayer have introduced nylon-based nanocomposites. Since
then, a large number of companies have been developing nanocomposites for commercial
applications. In the fall of 2001, GM with Basell launched the first commercial
automotive application of nanocomposite thermoplastic olefin. More recently,
widespread interest has been generated by carbon nanotubes as reinforcing fibers
for composites. Because of its unique geometry, potentially a new generation
of lightweight, high-strength composite can be produced.
This report will review the technological development in nanoparticles. It will
principally focus on nanocomposites produced with nanoparticles of clay where
most of the commercialization activities are occurring. Nanoclay and nanocomposite
production, product properties, potential applications, current markets and
producers will be reported. The process economics for production of nanoclay
and nanocomposites will be evaluated. The status of other potential nanofillers,
i.e., carbon nanotubes and polyhedral oligomeric silsesquioxanes, will be reviewed.
Because this report focuses on the status and future direction of polymer nanocomposites,
it will be of particular interest to producers of polyolefins.
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