Preparation, Characterization and Abrasion Resistance Property of Melamine Formaldehyde / Montmorillonite Nanocomposite Coatings

This study investigates preparation of melamine formaldehyde / montmorillonite nanocomposite coatings and evaluates its abrasion resistance property as a new material for wood based panel products. The ultrasonicated MF resin/clay blends with different clay loadings were applied in the form of coatings to the saturated decorative paper to prepare thermoset prepregs. Morphology and structure of nanocomposite coatings were characterized using X-ray diffraction and field emission scanning electron microscopy FE-SEM. Then viscoelastic properties of resultant prepregs were investigated using DMTA method. Tensile strength test was employed to determine tensile modulus and toughness of different prepregs. To evaluate abrasion resistance property of cured nanocomposite coatings, Taber abrasion test was performed on panels laminated with prepregs. The results showed that although modulus of storage stiffness and tensile strength of intercalated nanocomposite containing 4 clay was lower than that of partially exfoliated nanocomposite at 1 clay, its toughness and abrasion resistance property was amazingly better. This result of Taber abrasion test suggests the contribution of nanocomposite morphology to improving the abrasion resistance property in MF/montmorillonite nanocomposites instead of stiffness and strength. It was also found that there must be a relation between clay intercalated morphology in the nanocomposite structure and improving its toughness property. However, further research is needed to gain an in-depth understanding on its affecting mechanism.