Lightweight Nanocomposites for Missile Defense Applications

The key requirement for nanocomposite formation is dispersion of clay particles at nm length scales in polymer matrices, which is not trivial. Such a molecular-level dispersion necessitates complete exfoliation of clay particles, which occurs sporadicallywith the fabrication procedures currently in use. Based on a previously demonstrated concept, we propose to develop a novel nanocomposite fabrication method based on elongational flow that is potentially applicable to various high performance resinmatrices commonly used in composite fabrication. The primary objective of this proposal is to demonstrate that our novel concept of exfoliation by extesnional flow produces nanocomposites with greatly improved modulus, strength and thermal stability. Weintend to fabricate and test several artifacts such as films, coatings and molded articles to get a preliminary idea of their application potential, which is a corollary objective of this Phase I STTR.Polymer-clay nanocomposites possess mechanicalproperties that set them apart from conventional fiber-reinforced or mineral-filled materials in the sense that property enhancement in nanocomposites occurs at very low clay loadings, < 5 wt%. This means that superior performance can be realized withsignificant weight savings, which is highly desirable in ballistic missile applications, especially where high stiffness is required in thin-walled sections. Our approach calls for a simple, low-cost extension of existing resin manufacturing methods. Wetherefore believe that our novel approach to clay exfoliation has the potential to lead to several commercial applications including lightweight structural components with superior thermomechanical properties (automotive, aviation and missile defense),films with superior barrier resistance (packaging) and coatings containing high performance clay minerals (consumer goods and electrical/electronic).