Phenolic matrix nanocomposites based on commercial grade resols: Synthesis and characterization

Polymer layered silicate nanocomposites based on a commercial grade resol were produced using a simple, low labor cost, mechanical approach which allowed to avoid the process of intercalative polymerization of phenol and formaldehyde. Commercial compatibilized montmorillonite was selected as the main nanoreinforcement, while the matrix was a resol diluted in methanol. The aim of this work was to optimize the production technique of the above mentioned nanocomposites. Therefore intercalation of the resin was promoted by high speed mixing, and the processing parameters were varied in order to find the optimum dispersion. The produced nanocomposites were characterized and compared by means of X-ray diffraction, SEM and thermogravimetric analysis. The results of the characterization tests indicated that it was possible to obtain a good degree of dispersion as well as and uniform distribution of the nanoclay platelets. However, TGA measurements showed that the introduction of well dispersed nanoclays did not result in a consistent improvement of thermal stability respect that of the neat resol.