This article reviews the literature reports based on polystyrene nanocomposites using nanoclay as filler. The use of various clay surfactants and different processing conditions, i.e., in situ polymerization, melt intercalation and solution casting used for the preparation of nanocomposites and its effect on the properties and morphology is also reviewed.

With production of nanocomposites, the product life cycle, including recycling, becomes critical.

Roll-to-roll hot embossing could revolutionize the manufacturing of multifunctional polymer films with the ability to process large area at a high rate with reduced cost. The continuous hot embossing of the films, however, has been hindered due to the lack of durable and flexible molds, which can replicate micro and nanofeatures with reliability over several embossing cycles. In this work, we demonstrate for the first time the fabrication of a flexible polymer (polyimide) mold from the commercially available sheet by a maskless photolithography approach combined with inductively coupled plasma etching and its potential application to the roll-to-roll hot embossing process. The flexible polyimide mold consisted of holes with controlled dimensions: diameter: 14 μm, spacing: 16.5 μm, and depth: 6.8 μm. The reliability of flexible polyimide mold was tested and implemented by embossing micron-sized features on a commercial thermoplastic polymer, polyamide, and thermoplastic elastomer (TPE) sheet. The polyimide mold replicated micron-sized features on polymer substrates (polyamide and TPE) with excellent fidelity and was durable even after numerous embossing cycles.

Transparent optical polymer/filler systems can be produced into complex shapes for a range of applications, such as lenses, shields, and containers. This work used refractive index liquids as a model for polymer matrices to investigate the degree of refractive index match required to maintain high transmission in an inorganic-filled polymer system (cubic calcium fluoride with particle size of 1 to 5 µm) over the visible spectrum. It was determined that in order to achieve a transparent composite (>85% transmission with 10 mm pathlength) with this filler (using literature reported dispersion data), the materials must have a refractive index match within ±0.007 for 1.6 vol.% loading. With a loading of 3.1 vol.%, the matching range required was reduced to approximately ±0.002.