Abstract
Room-temperature self-healing polyurethanes (PUs) generally show limited mechanical properties. In order to improve the mechanical properties of PUs without sacrificing their self-healing ability, in this study, different amounts of halloysite clay filler were added. Thus, intrinsically self-healing PUs were synthesized using polycarbonate diol polyol, aliphatic diisocyanate, 1,4-butanediol, and different amounts (0.5-10 wt.%) of thermally treated halloysite. During synthesis, the halloysite clay was added to the polyol. The structural, thermal, viscoelastic, and mechanical properties of the resulting halloysite-filled PUs were evaluated. All halloysite-filled PUs retained their room-temperature self-healing capability while exhibiting improved mechanical strength. The PU with 0.5 wt.% halloysite (E0.5) showed the most balanced performance, with well-dispersed halloysite nanotubes intercalated within the soft segments, enhancing chain mobility and soft segment ordering. Higher halloysite loadings (1-3 wt.%) led to increased mechanical properties but also some round clay particle agglomeration and surface migration, leading to limited halloysite-polyurethane interactions. The addition of more than 3 wt.% halloysite did not result in further improvements in mechanical properties. The findings of this study provide new insight into the filler-polymer interaction mechanism and establish a foundation for the design of multifunctional PUs with both autonomous self-repair and enhanced mechanical performance.