Preparation of urea formaldehyde resin/layered silicate nanocomposites

Abstract

PurposeThe purpose of the research was as follows. In situ modified urea formaldehyde resins were prepared from clay (montmorillonite) and organoclay in the presence of base catalyst. Different clay contents (1 wt%, 3 wt%, 6 wt%) were used to produce clay modified nanocomposite resins. These nanocomposites were characterized with FT‐IR, XRD as structural analysis and DSC as thermal analysis and their hardness was evaluated as mechanical analysis. The thermal results was compatible with hardness measurements and showed that using clay/organoclay added resin as a surface coating material provides significant improvement.Design/methodology/approachDuring synthesis of the resin, modification was carried out using urea/formaldehyde with molar ratio of 1/1.6, under basic medium with pH=10 and with temperature of 70°C by loading pristine and organomodified layered silicates.FindingsX‐ray diffraction (XRD) results indicate that the interlayer space of pristine clay was increased significantly by one step, seeing that one step processes are crucial for industrial applications.Research limitations/implicationsThe reaction mixture must be stirred continuously. Temperature should be controlled in order to prevent the thermal curing of urea formaldehyde resin.Practical implicationsThis study provides technical information for the synthesis of nanocomposite resins. The clay or organoclay modified resins may also promote the adhesive strength of coating and also inhibit corrosion effects to metal surfaces of the coated area.Social implicationsThis resin will be used for the coating material.Originality/valueAs Tg‐Tm region of some nanocomposites is enhanced, and by assessing the results of hardness measurements, it is concluded that these samples have further improved mechanical properties as a coating material than urea formaldehyde resin has.