Mechanical performance of ternary in situ polycarbonate/poly(acrylonitrile‐butadiene‐styrene)/liquid crystalline polymer composites

Ternary in situ polycarbonate (PC)/poly(acrylonitrile‐butadiene‐styrene) (ABS)/liquid crystalline polymer(LCP) composites were prepared by injection molding. The LCP used was a versatile Vectra A950, and the matrix of composite specimens was PC/ABS 60/40 by weight. Maleic anhydride (MA) copolymer and solid epoxy resin (bisphenol type‐A) were used as compatibilizers for these composites. The tensile, dynamic mechanical, impact, morphology, and thermal properties of the composites were studied. Tensile tests showed that the tensile strength of the PC/ABS/LCP composite in the longitudinal direction increased markedly with increasing LCP content. However, it decreased slowly with increasing LCP content in the transverse direction. The modulus of this composite in the longitudinal direction appeared to increase considerably with increasing LCP content, whereas the incorporation of LCP into PC/ABS blends had little effect on the modulus in the transverse direction. The impact tests revealed that the Izod impact strength of the composites in both longitudinal and transverse direction decreased with increasing LCP content up to 15 wt %; thereafter it increased slowly with increasing LCP. Dynamic mechanical analyses (DMA) and thermogravimetric measurements showed that the heat resistance and heat stability of the composites tended to increase with increasing LCP content. Scanning electron microscopy observation and DMA measurement indicated that the additions of epoxy and MA copolymer to PC/ABS matrix appeared to enhance the compatibility between the PC and ABS, and between the matrix and LCP. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 2274–2282, 1999     

In‐situ reinforcement of PBT/ABS blends with liquid crystalline polymer

Ternary in‐situ poly(butylene terephthalate) (PBT)/poly(acrylonitrile‐butadienestyrene) (ABS)/liquid crystalline polymer(LCP) blends were prepared by injection molding. The LCP used was a versatile Vectra A950, and the matrix material was PBT/ABS 60/40 by weight. Maleic anhydride (MA) copolymer and solid epoxy resin (bisphenol type‐A) were used as compatibilizers for these blends. The tensile, dynamic mechanical, impact, morphology and thermal properties of the blends were studied. Tensile tests showed that the tensile stregth of PBT/ABS/LCP blend in the longitudinal direction increased markedly with increasing LCP content. However, it decreased sharply with increasing LCP content up to 5 wt%; thereafter it decreased slowly with increasing LCP content in the transverse direction. The modulus of this blend in the longitudinal direction appeared to increase considerably with increasing LCP content, whereas the incorporation of LCP into PBT/ABS blends had little effect on the modulus in the transverse direction. The impact tests revealed that the Izod impact strength of the blends in longitudinal direction decreased with increasing LCP content up to 10 wt%; thereafter it increased slowly with increasing LCP. Dynamic mechanical analyses (DMA) and thermogravimetric measurements showed that the heat resistance and heat stability of the blends tended to increase with increasing LCP content. SEM observation, DMA, and tensile measurement indicated that the additions of epoxy and MA copolymer to PBT/ABS matrix appeared to enhance the compatibility between PBT/ABS and LCP.     

Study on in situ reinforcing and toughening of a semiflexible thermotropic copolyesteramide in PBT/PA66 blends

Ternary in situ composites based on poly(butylene terephthalate) (PBT), polyamide 66 (PA66), and semixflexible liquid crystalline polymer (LCP) were systematically investigated. The LCP used was an ABA30/PET liquid crystalline copolyesteramide based on 30 mol % of p‐aminobenzoic acid (ABA) and 70 mol % of poly(ethylene terephthalate) (PET). The specimens for thermal and rheological measurements were prepared by batch mixing, while samples for mechanical tests were prepared by injection molding. The results showed that the melting temperatures of the PBT and PA66 phases tend to decrease with increasing LCP addition. They also shifted toward each other due to the compatibilization of the LCP. The torque measurements showed that the ternary blends exhibited an apparent maximum near 2.5–5 wt % LCP. Thereafter, the viscosity of the blends decreased dramatically at higher LCP concentrations. Furthermore, the torque curves versus the PA66 composition showed that the binary PBT/PA66 blends can be classified as negative deviation blends (NDBs). The PBT/PA66/LCP blends containing up to 15 wt % LCP were termed as positive deviation blends (PDBs), while the blends with the LCP ≥25 wt % exhibited an NDB behavior. Finally, the tensile tests showed that the stiffness and tensile strength of ternary in situ composites were generally improved with increasing LCP content. The impact strength of ternary composites initially increased by the LCP addition, then deteriorated when the LCP content was higher than 10 wt %. The correlation between the mechanical properties and morphology of the blends is discussed. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 1975–1988, 2000     

In situ reinforcement of poly(butylene terephthalate) and butyl rubber by liquid crystalline polymer

Ternary in situ butyl rubber (IIR)/poly(butylene terephthalate) (PBT) and liquid crystalline polymer (LCP) blends were prepared by compression molding. The LCP used was a versatile Vectra A950, and the matrix material was IIR/PBT 50/50 by weight. Morphological, thermal, and mechanical properties of blends were investigated using scanning electron microscopy (SEM), atomic force microscopy (AFM), differential scanning calorimetry, and thermogravimetric analysis (TGA). Microscopy study (SEM) showed that formation of fibers is increasing with the increasing amount of LCP A950. Microscopic examination of the fractured surface confirmed the presence of a polymer coating on LCP fibrils. This can be attributed to some interactions including both chemical and physical one. The increased compatibility in polymer blends, consisting of IIR/PBT, by the presence of LCP A950 may be explained by the adsorption phenomena of the polymer chains onto the LCP fibrils. SEM and AFM images provided the evidence of the interaction between IIR/PBT and the LCP. Dynamic mechanical analyses (DMA) and TGA measurements showed that the composites possessed a remarkably higher modulus and heat stability than the unfilled system. Storage modulus for the ternary blend containing 50 wt% of LCP exhibits about 94% increment compared with binary blend of IIR/PBT. From the above results, it is suggested that the LCP A950 can act as reinforcement agent in the blends. Moreover, the fine dispersion of LCP was observed with no extensional forces applied during mixing, indicating the importance of interfacial adhesion for the fibril formation. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

Injection molding of PC/PBT/LCP ternary in situ composite

A liquid crystalline polymer (LCP), Vectra B950, reinforced polycarbonate (PC) 60 wt%/polybutylene terephthalate (PBT) 40 wt% blend was studied using the injection molding process. Morphology and mechanical properties of ternary in situ LCP composites were investigated and compared with binary polycarbonate/Vectra B950 LCP composites. Good in situ fibrillation of LCP was observed in the direct injection-molded LCP composites. Preliminary results of this work indicate that addition of PBT improves skin-core distribution of LCP microfibrils in the matrix and also enhances adhesion between the matrix and Vectra B950, which contains terephthalic acid. The PC/PBT/LCP ternary system also exhibits lower viscosity than the PC/PBT blend and pure LCP. In a ternary system with 30 wt% of Vectra B950, tensile modulus and strength increase approximately threefold and twofold, respectively. The rule of mixtures (ROM) for continuous reinforcement can accurately represent the strengthening effects for the ternary LCP in situ composites. Generally, LCP reduces the ductility and impact strength of the thermoplastic blends; however, the relative loss is less in the ternary system than in the binary system.     

Reinforcement of polyamide 6 with thermotropic liquid crystalline polymer

The in-situ composites of polyamide 6 (PA 6)/liquid crystalline polymer (LCP) were investigated from the standpoint of fibrillation of LCP to develop a new high performance gear material for heavy load use that is superior to conventional plastic gears made of polyacetal (POM). LCP used was a wholly aromatic copolyester. PA 6 was chosen as the matrix polymer because of its excellent fatigue resistance. Extrusion of PA 6 added with LCP from 10 to 30 vol% was carried out at a temperature between 260 and 290°C by a twin screw extruder and take-up equipment. Insitu fibrillation of LCP droplets, which were dispersed in PA 6 matrix, took place during the process. Injection molding of the composites was followed at a temperature below the softening point of LCP fibrils so as to keep the fibrils as extruded. Key factors for fibrillation of LCP were found as follows: (1) control of stress relaxation of LCP when the melt passes through the die-head, (2) the optimum temperature of nent, (3) the optimum LCP content, and (4) addition of a small amount of 3rd component. A gear made of in-situ composite of PA 6/LCP (30 vol%) added with 2-functional epoxy resin (2.5 phr) was found to bear a load about 1.2 times heavier than a POM gear.     

Factors influencing microstructure formation in polyblends containing liquid crystalline polymers

Four isotropic polymers, poly(butylene terephthalate) (PBT), polycarbonate (PC), polyethersulfone (PES) and polysulfone (PSU), were blended by extrusion with a thermotropic liquid crystalline polymer (LCP) at different temperatures. The morphology of extrudates was observed by means of scanning electron microscopy and the intrinsic aspect ratio of LCP fibrils and particles separated from matrix resin was measured with an image analysis. Special attention was paid to the LCP fibrillation in these four matrices in a wide temperature range from 270 to 360°C and the internal relations among the effects of processing parameters, such as viscosity ratio, extrusion temperature, and LCP concentration. The results show that the viscosity ratio of the dispersed LCP phase to the continuous phase is a decisive factor determining the formation of LCP fibrils, but its effect closely relates with the LCP content. In the range of viscosity ratios investigated, 0.004 to 6.9, and lower LCP content of 10%, significant fibrillation took place only at viscosity ratios below 0.01. It is predicted that the upper limit of the viscosity ratio for LCP fibrillation will increase with increasing LCP content. A comparison of the morphologies of LCP/PES blends with different LCP concentrations reveals that the LCP phase becomes continuous at a concentration of less than 50%, and high LCP content does not always favor the formation of long and uniform LCP fibrils. The extrusion temperature has a marked effect on the size of the minor LCP domains. For fibril forming systems, the percentage of LCP fibrils with larger aspect ratios increases with increasing extrusion temperatures. All these results are explained by the combined role of deformation and coalescence of the LCP disperesed phase in the blend.     

Use of epoxy reactivity for compatibilization of PP/PBT and PP/LCP blends

Binary blends of a reactive ethylene-based terpolymer with polybutylene terephthalate (PBT) and with a liquid crystalline polyester (LCP) were studied to clarify the possible interactions between the blended polymers. The aim was to determine the suitability of the reactive terpolymer containing epoxy reactivity as a compatibilizer in blends of polypropylene (PP) and these two polyesters. The binary blends exhibited increased viscosity during blending, changes in the crystallization of the PBT phase, and an intimate contact between the blended polymers, which pointed to strong interactions or chemical reactions between the compatibilizer and both PBT and LCP. FTIR analysis confirmed the reaction of the epoxide and formation of new esters. Most probably the carboxyl end groups of the polyesters reacted with the epoxy group of the compatibilizer. In the second part of the work the same terpolymer was shown to act as a compatibilizer in PP/PBT and PP/LCP blends. This behavior was based on good mixing with the PP phase and on the chemical reactivity or strong interactions with the polyesters demonstrated in the investigations on binary blends. Addition of 5 wt% of the compatibilizer improved the impact strength, especially in PP/PBT blends where synergistic behavior was found at compositions of 80/20 and 20/80. In PP/LCP blends, the compatibilizer significantly improved the impact strength of unnotched samples at 20 wt % LCP content. In both blends, the compatibilizer reduced the size of the dispersed domains and caused them to attach better in the matrix. © 1995 John Wiley & Sons, Inc.     

In situ composites from blends of polycarbonate and a thermotropic liquid‐crystalline polymer: The influence of the processing temperature on the rheology,morphology, and mechanical properties of injection‐molded microcomposites

This work was aimed at understanding how the injection‐molding temperature affected the final mechanical properties of in situ composite materials based on polycarbonate (PC) reinforced with a liquid‐crystalline polymer (LCP). To that end, the LCP was a copolyester, called Vectra A950 (VA), made of 73 mol % 4‐hydroxybenzoic acid and 27 mol % 6‐hydroxy‐2 naphthoic acid. The injection‐molded PC/VA composites were produced with loadings of 5, 10, and 20 wt % VA at three different processing barrel temperatures (280, 290, and 300°C). When the composite was processed at barrel temperatures of 280 and 290°C, VA provided reinforcement to PC. The resulting injection‐molded structure had a distinct skin–core morphology with unoriented VA in the core. At these barrel temperatures, the viscosity of VA was lower than that of PC. However, when they were processed at 300°C, the VA domains were dispersed mainly in spherical droplets in the PC/VA composites and thus were unable to reinforce the material. The rheological measurements showed that now the viscosity of VA was higher than that of PC at 300°C. This structure development during the injection molding of these composites was manifested in the mechanical properties. The tensile modulus and tensile strength of the PC/VA composites were dependent on the processing temperature and on the VA concentrations. The modulus was maximum in the PC/VA blend with 20 wt % VA processed at 290°C. The Izod impact strength of the composites tended to markedly decrease with increasing VA content. The magnitude of the loss modulus decreased with increasing VA content at a given processing temperature. This was attributed to the anisotropic reinforcement of VA. Similarly, as the VA content increased, the modulus and thus the reinforcing effect were improved comparatively with the processing temperature increasing from 280 to 290°C; this, however, dropped in the case of composites processed at 300°C, at which the modulus anisotropy was reduced. Dynamic oscillatory shear measurements revealed that the viscoelastic properties, that is, the shear storage modulus and shear loss modulus, improved with decreasing processing temperatures and increasing VA contents in the composites. Also, the viscoelastic melt behavior (shear storage modulus and shear loss modulus) indicated that the addition of VA changed the distribution of the longer relaxation times of PC in the PC/VA composites. Thus, the injection‐molding processing temperature played a vital role in optimizing the morphology‐dependent mechanical properties of the polymer/LCP composites. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Microstructural and mechanical characteristics of compatibilized polypropylene hybrid composites containing potassium titanate whisker and liquid crystalline copolyester

Maleic anhydride (MA) compatibilized polypropylene (MPP) hybrid composites reinforced with potassium titanate whiskers (K₂Ti₆O₁₃) and liquid crystalline polymer (LCP) were prepared in a twin-screw extruder followed by injection molding. The surface of whiskers were treated with tetrabutyl orthotitanate before blending. Scanning electron microscopic (SEM) examination showed that elongated LCP fibrils are formed in the skin section of hybrids reinforced with whiskers of various concentrations. Consequently, the hybrids reinforced with both LCP fibrils and whiskers exhibited anisotropic mechanical properties. Tensile test showed that longitudinal Young’s modulus and tensile strength of hybrids tend to increase with increasing whisker content. Moreover, the stiffness and tensile strength of hybrids were higher than those of MPP/K₂Ti₆O₁₃ composites. Such enhancement in mechanical properties resulted from the compatibilizing effect of MA-grafted-PP, and from the hybrid reinforcing effect of LCP fibrils and K₂Ti₆O₁₃ whiskers. Torque measurements revealed that LCP addition is beneficial in reducing the melt viscosity of MPP/K₂Ti₆O₁₃/LCP hybrids. The results of SEM observations generally correlate well with the mechanical measurements. The effects of MA compatibilization on the microstructure and mechanical properties of hybrids are discussed.     

Structure and properties of molded polyblends containing liquid crystalline polymers

The relationship between the microstructure developed during injection molding of liquid crystalline polymers (LCPs) containing blends and their mechanical properties, was studied. A wholly aromatic copolyester LCP was melt blended in various levels with polycarbonate (PC), poly(butylene terephthalate) (PBT), Nylon 6 (N-6), and amorphous nylon (AN). In all cases the LCP was the minor component. The resulting injection molded structure had a distinct skin core morphology, where elongated fibrous LCP particles comprised the skin layer and spherical and ellipsoidal ones composed the core section. The highest elongation and the finest diameter LCP fibrils were obtained with AN/LCP system, followed by PC/LCP. PBT/LCP blends showed a coarser morphology, while N-6/LCP system did not correlate with the tensile moduli of the injection molded specimens. AN/LCP blends demonstrated the highest moduli values, consistent with the highest orientations observed using electron microscopy, followed by PC/LCP, PBT/LCP, and N-6/LCP. Finally, tensile strength levels were correlated with both orientation levels and interfacial adhesion between the polyblend components. AN/LCP that exhibited the highest orientation and good adhesion appearance gave the highest tensile strength values followed by PC/LCP, PBT/LCP, and N-6/LCP polyblends.     

Compatibilizing effect of styrene–maleic anhydride copolymer on the properties of polyamide‐6/liquid crystalline copolyester composites

Liquid crystalline polymer–polyamide‐6 (LCP/PA6) composites containing 20 wt % LCP content were compatibilized by a random styrene–maleic anhydride copolymer (RSMA). The blending was performed via extrusion followed by injection molding. The LCP employed was a commercial copolyester, Vectra A950. The dynamic mechanical (DMA), rheological, thermal, and mechanical properties as well as the morphology of the composites were studied. The DMA and rheological results showed that RSMA is an effective compatibilizer for LCP/PA6 blends. The mechanical measurements showed that the stiffness, tensile strength, and toughness of the in situ composites are generally improved with increasing RSMA content. However, these mechanical properties deteriorated considerably when RSMA content was above 10 wt %. The drop‐weight dart impact test was also applied to analyze the toughening behavior of these composites. The results show that the maximum impact force (F_max) and crack‐initiation energy (E_init) tend to increase with increasing RSMA content. From these results, it appeared that RSMA prolongs the crack‐initiation time and increases the energies for crack initiation and impact fracture, thereby leading to toughening of LCP/PA6 in situ composites. Finally, the correlation between the mechanical properties and morphology of the blends is discussed. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 1964–1974, 2000     

Morphology evolution of a liquid crystalline polymer confined by highly packed glass beads in polycarbonate

Very long and perfectly oriented fibrils of a liquid crystalline polymer (LCP) were in situ formed in capillary flows by adding large amounts of glass beads (GB) to a polycarbonate (PC)/LCP blend. Thermodynamically the different interfacial tensions between the components made GB migrate to the LCP phase. Then the high content of GB spheres produced a confined condition, so that the LCP droplets passed through the simultaneously formed micro-capillaries, followed by being stretched into fibrils and stabilized consequently.     

TP／LCP原位复合材料

综述了以PP、PET、PC等几种常见的热塑性高聚物为基体的LCP(液晶共聚酯)原位复合材料,讨论了TP(热塑性高聚物)/LCP的结构与性能以及TP与LCP之间的相容性。     

Molecular orientation and mechanical properties of polymer blends of PBT and a liquid crystalline polyester

A thermotropic liquid crystalline polyester (LCP) based on 4-hydroxyacetophenone azine and sebacoyl dichloride was synthesized via a low-temperature solution route. The liquid crystalline polymer was characterized by ¹H-NMR, DSC, GPC, and polarizing microscopy experiments. The LCP was melt-blended with poly(butylene terephthalate) (PBT), followed by the melt-spinning process at take-up speeds ranging from 14 to 50 m/min. We analyzed the molecular orientational order of LCP and PBT in as-spun fibers of the LCP/PBT blends by the attenuated total reflection (ATR) FTIR dichroism technique and WAXS. The order parameter (S), representing the molecular orientational order, of LCP in the polyblend fibers increased as the employed LCP amounts and the draw ratio increased. Moreover, the order parameter of PBT in the blends increased dramatically when sufficiently large amounts of LCP (over 50 wt %) were employed, especially for highly drawn fibers, which suggested a considerable miscibility between LCP and PBT. The thermal behavior of the blends investigated by DSC also indicated that the synthesized LCP was miscible, at least partially, with PBT. All these results correlated with the enhancement of mechanical properties observed for higher concentrations of LCP in the blends and for highly drawn samples. © 1996 John Wiley & Sons, Inc.     

Novel approach to fibrillation of LCP in an LCP/PP blend

A novel concept of improving shear‐induced fibrillation of liquid crystalline polymer (LCP) in LCP/thermoplastic blend systems was introduced. Silica fillers (SiO₂) were added to an LCP/polypropylene (PP) system to serve as a viscosity thickening agent and to improve the fibrillation of the LCP phase. The formation of LCP fibrils was found to enhance with the incorporation of 5–15 wt % of fillers. The presence of LCP fibrils improved the flow properties of the LCP/PP/SiO₂ composites. It was evident from the rheological and morphological studies that the addition of silica led to an increase of the aspect ratio of the LCP fibrils, which, in turn, should improve their effectiveness as reinforcements and/or toughening agents. Substantial improvement in LCP aspect ratio was achieved by the introduction of hydrophobic SiO₂ fillers in the PP/LCP blends. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 2070–2078, 2002     

Preparation,morphology, and properties of silane‐modified MWCNT/epoxy composites

Both epoxy resin and acid‐modified multiwall carbon nanotube (MWCNT) were treated with 3‐isocyanatopropyltriethoxysilane (IPTES). Scanning electron microscopy (SEM) and transmission electronic microscope (TEM) images of the MWCNT/epoxy composites have been investigated. Tensile strength of cured silane‐modified MWCNT (1.0 wt %)/epoxy composites increased 41% comparing to the neat epoxy. Young's modulus of cured silane‐modified MWCNT (0.8 wt %)/epoxy composites increased 52%. Flexural strength of cured silane‐modified MWCNT (1.0 wt %)/epoxy composites increased 145% comparing to neat epoxy. Flexural modulus of cured silane‐modified MWCNT (0.8 wt %)/epoxy composites increased 31%. Surface and volume electrical resistance of MWCNT/epoxy composites were decreased with IPTES‐MWCNT content by 2 orders and 6 orders of magnitude, respectively. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Ternary blends of acrylic rubber,poly(butylene terephthalate), and liquid crystalline polymer: Influence of interactions on thermal and dynamic mechanical properties

The ternary blends of acrylate rubber (ACM), poly(butylene terephthalate) (PBT), and liquid crystalline polymer (LCP) were prepared by varying the amount of LCP but fixing the ratio of ACM and PBT, using melt mixing procedure. The influence of interactions on thermal and dynamic mechanical properties of the blends was investigated over the complete composition range. The techniques applied were Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), thermogravimetry (TG), and dynamic mechanical analysis (DMA). The FTIR spectroscopy analysis showed reduction in the intensity of the peak corresponding to epoxy groups of ACM with increasing heating time at 290°C. This implies that there is a chemical reaction between the epoxy and end groups of PBT and LCP. Glass transition temperature (T_g) and melting temperature (T_m) of the blends were affected depending on the LCP weight percent in the ACM/PBT blend, respectively. This further suggests the strong interfacial interactions between the blend components. In presence of ACM, the nucleating effect of LCP was more pronounced for the PBT phase. The thermogravimetric study showed improved thermal stability for the blends with the increasing LCP content. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3904–3912, 2006     

Reactive compatibilization of the poly(ethylene terephthalate)/liquid crystalline polymer blends by solid epoxy resin as a coupling agent

A selected reactive coupling agent can be served as an effective compatibilizer for certain immiscible and incompatible blends should both blend constituents possess the necessary functional groups that can react with the coupling agent at comparable rates. Solid epoxy resin with two epoxide endgroups per molecule was demonstrated to be an efficient reactive compatibilizer for the incompatible blends of poly(ethylene terephthalate) (PET) and copolyester liquid crystalline polymer (LCP) by functioning as a coupling agent. The main chain structure of the epoxy resin is neither identical not miscible with PET and LCP and tends to reside at interface during melt mixing. This preferential residence gives the epoxy compatibilizer greater opportunity to react with both PET and LCP simultaneously to produce the in situ–formed epoxy-b-LCP mixed copolymer. This in situ–formed mixed copolymer is highly effective in compatibilizing the PET/LCP blends. This reactive epoxy compatibilizer enhances the LCP fibril formation and results in substantial improvements on stiffness and toughness of the PET/LCP blends. © 1996 John Wiley & Sons, Inc.     

Fiber reinforcement and fracture resistance of PC/PBT/LCP ternary in situ composite

The microstructures, mechanical properties, and fracture toughness of LCP (Vectra B950) reinforced PC/PBT blend with a 60/40 weight ratio have been studied. LCP of varying concentrations were investigated as rigid fillers in matrices of multiphase polymer blends. In this study, differences in microstructures and morphology between samples of two thicknesses (4 mm thick and 6 mm thick) and two geometries (dumbbell and rectangular) were compared using scanning electron microscopy (SEM). Given identical processing conditions, fibrous LCP structures were evident in the 4-mm-thick injection molded, dumbbell-shaped samples, whereas the 6-mm-thick rectangular samples displayed spherical dispersion of LCP aggregates that embrittled the preblended ductile matrix. Tensile properties of the dumbbell specimens showed superior strengthening and stiffening whereby the tensile strength increased twofold and the modulus increased fourfold. Plane strain fracture toughness was slightly enhanced as the LCP content increased because of the fiber strengthening effect but the overall fracture performance of the in situ composites was relatively poor compared with PC/PBT. Experimental results were compared with those predicted in composite theory. Simplified micromechanics equations were developed to describe the tensile moduli of injection molded LCP reinforced blends that exhibited a strong skin-core morphology.