The aim of the current study was to first make two compatibilizers, i.e., maleic anhydride grafted polypropylene (PP-g-MA), based on a homo-and a block copolymer. Then, these custom made compatibilizers were incorporated in PP/nanoclay composites made via direct and two-step masterbatch techniques. The influence of compatibilizer/nanoclay ratio was examined in the direct method. In the two-step processing technique, the
compatibilizer content was divided to two parts such that the first part was used when making the masterbatch and the second part was incorporated in the second step when the masterbatch was diluted by the polymer matrix. The characterizations via titration test and Fourier-transform infrared (FTIR) spectroscopy revealed a higher degree of grafting reaction when homo-polymer was used for synthesizing PP-g-MA. In the next step, nanocomposites containing ۳ wt.% nanoclay with three different PP-g-MA (both types)/nanoclay ratios of ۱:۱, ۲:۱, and ۳:۱ were made using a co-rotating twin screw extruder. X-ray diffraction (XRD) analysis was done to evaluate morphology and tensile and impact, and tests were performed to evaluate the
mechanical properties of the PP samples. Based on the results, maleic anhydride grafted homo-polypropylene (HPP-g-MA) and the composition containing HPP-g-MA/nanoclay ratio of ۲:۱ with ۷.۶۹% improvement in Young’s modulus was reported as the recommended
compatibilizer and ratio for applications. Finally, five nanocomposite samples with identical composition were made in two steps. A masterbatch containing ۱۵ wt.% nanoclay was made first and then, it was diluted with PP to reduce the nanoclay content to ۳ wt.%. All samples containing ۶ wt.% PP-g-MA, but the method of addition of
compatibilizer was different. In one sample, the whole
compatibilizer was added into the masterbatch. In another sample, the entire PP-g-MA was added in the second stage of compounding. In the other three samples, the addition of
compatibilizer was divided between the two stages of the process. The results of the study showed that the highest improvement of elastic modulus (۲۴.۲۶%) was obtained when the majority of the
compatibilizer was added in the second step of production. This was associated with the best dispersion of nanoclay platelets in the PP matrix.
