in exfoliation the clay galleries expands which gives way to polymer chains to occupy the free space and in case of intercalation of nanoclay the polymer chains gets between the unexpanded galleries, which is very small (around 1 nm)?
When the silicate layers are completely and uniformly dispersed in a continuous polymer matrix, an exfoliated or delaminated structure is obtained. In the case of exfoliated structures, extensive layer separation associated with delamination of the original silicate structure in the polymer matrix leads to the disappearance of any coherent x-ray scattering from the layers. In this case you will obtain a maximum surface area of the nanoclay which can contact with the polymer. However to achieve a better mechanical properties you also need to have a good interface interaction between your polymer and exfoliated clay layers.
Refer this link:https://books.google.co.in/books?id=HLo0CgAAQBAJ&pg=PA19&lpg=PA19&dq=exfoliation+of+nanoclay+yields+better+mechanical+properties&source=bl&ots=vOdEztfLob&sig=SxpzupU1_6Dn5HIlTGd_a7NHP-o&hl=en&sa=X&ved=0CC8Q6AEwAmoVChMItaHmmezfyAIViiSUCh0TJgmW#v=onepage&q=exfoliation%20of%20nanoclay%20yields%20better%20mechanical%20properties&f=false
If you read about nano particles you will find lesser the size more the number of nanoparticles on the surface. This ensures the interface among polymer chain and exfoliated nano clay platelets will share very high interface area. The mechanical load is mostly born by exfoliated platelet as it is much stronger partner. This ensures that any mechanical stress is promptly passed on to stronger partner nanoclay. Thus much higher mechanical property is ensured for the nanocomposite than the polymer alone.
When the silicate layers are completely and uniformly dispersed in a continuous polymer matrix, an exfoliated or delaminated structure is obtained. In the case of exfoliated structures, extensive layer separation associated with delamination of the original silicate structure in the polymer matrix leads to the disappearance of any coherent x-ray scattering from the layers. In this case you will obtain a maximum surface area of the nanoclay which can contact with the polymer. However to achieve a better mechanical properties you also need to have a good interface interaction between your polymer and exfoliated clay layers.