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The Impact of Organoclay on the Physical and Mechanical Properties of Epoxy-Clay Nanocomposite Coatings

Nanocomposite coatings have recently been of interest because of their superior technical, environmental and economical advantages. Some new solvent free nanocomposite coatings were formulated using epoxy resin and montmorillonie (MMt) nanoclay. The organomodified MMt was well dispersed and partially exfoliated in the epoxy resin. The dispersion process comprised high-shear mixing and ultrasonication. The structure of the resultant coatings was characterized by transmission electron microscopy (TEM) and X-ray diffraction (XRD) analyses. The effect of the clay content on the physical and mechanical properties of the resultant coatings, such as abrasion and impact resistance, hardness, and flexibility were measured and compared with unmodified coatings. The introduction of organoclay up to 4 wt% in coating systems resulted in improvement in the physical and mechanical properties such as hardness (micro and König) and abrasion resistance. Also an increment of up to 3 wt% of organoclay leads to an increase in the impact resistance and flexibility of resultant coating films. On the other hand, flexibility and impact resistance of the coatings containing more than 3 wt% of clay was decreased. The main reason for these observations was agglomeration of the clay particles for high clay-loading compositions.