Synthesis and characterization of poly(butylene terephthalate)/mica nanocomposite fibers via in situ interlayer polymerization

Intercalated nanocomposites consisting of poly(butylene terephthalate) (PBT) incorporated between mica layers were synthesized from dimethyl terephthalate (DMT) and 1,4-butanediol (BD) by in situ interlayer polymerization. PBT nanocomposites of varying organoclay content were melt-spun to produce monofilaments. The samples were characterized using wide angle X-ray diffraction, electron microscopy, thermal analysis, and tensile testing. Some of the clay particles were found to be well dispersed in the PBT matrix, but other clay particles were agglomerated at a size level greater than approximately 20 nm. The glass transition temperatures (T-g) and the thermal degradation properties (T-D(i)) of undrawn PBT hybrid fibers were found to improve with increases in the clay content. At draw ratio (DR) = 1, the ultimate tensile strengths of the hybrid fibers increased with the addition of clay up to a critical content and then decreased. However, the initial moduli monotonically increased with increases in the amount of organoclay in the PBT matrix. The ultimate strengths were found to decrease linearly with increases in DR from I to 18. In contrast to the trend for the tensile strengths, the initial moduli of the hybrid fibers increased only slightly with increases in DR up to 18. (C) 2007 Wiley Periodicals, Inc.