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The interfacial interaction and orientation of filler play important roles in the enhancement of mechanical performances for polymer/inorganic filler composites. Shear has been found to be a very effective way for the enhancement of interfacial interaction and orientation. In this work, we will report our recent efforts on exploring the development of microstructure of high density polyethylene (HDPE)/mica composites in the injection‐molded bars obtained by so‐called dynamic packing injection molding (DPIM), which imposed oscillatory shear on the melt during the solidification stage. The mechanical properties were evaluated by tensile testing and dynamic mechanical analysis (DMA), and the crystal morphology, orientation, and the dispersion of mica were characterized by scanning electron microscopy and two‐dimensional wide‐angle X‐ray scattering. Compared with conventional injection molding, DPIM caused an obvious increase in orientation for both HDPE and mica. More importantly, better dispersion and epitaxial crystallization of HDPE was observed on the edge of the mica in the injection‐molded bar. As a result, increased tensile strength and modulus were obtained, accompanied with a decrease of elongation at break. The obtained data were treated by Halpin–Tsai model, and it turned out that this model could be also used to predict the stiffness of oriented polymer/filler composites. Copyright © 2009 John Wiley & Sons, Ltd.

In this paper, rheological properties evolution of the simple mixed isotactic polypropylene/organoclay composites, impacted by intermediate- or large-amplitude oscillatory shear fields, was followed by dynamic melt rheometry. The physical meanings of such rheological evolution upon oscillatory shearing, which related closely to the dispersion and intercalation of organoclay in polymer, were discussed deeply. Especially, a structural recovery test was adopted to assess microstructure development induced by large-amplitude oscillatory shear and to better understand the intercalation mechanism. Based on the experimental results, a novel intercalation mechanism that was taken to account for the disentanglement of polymer chains was suggested to describe shear-induced dispersion behaviors of organoclay in polymer matrix.

Melt mixing with a polymer is a novel strategy to modify the surface property of carbon nanotube (CNT) conveniently and efficiently. In melt mixing process, the shearing and thermal issues can make polymer component wrapped around nanotubes via π–π stacking interaction. In this study, polystyrene‐coated multi‐walled carbon nanotubes (MWNTs) was achieved through simple melt mixing of polystyrene with MWNTs. PS and MWNTs were first melt mixed at various melt time and temperatures to find the optimum condition for preparing of PS‐coated MWNTs. Subsequently, the stability of polystyrene interacted with MWNTs was estimated via ultrasonication and thermal gravimetric analysis (TGA). Finally, the physically modified MWNTs were used to enhance polystyrene. An obvious mechanical reinforcement can be achieved, which approves a huge potential of application of these modified MWNTs in practical composite products. Copyright © 2009 John Wiley & Sons, Ltd.