Quantitative prediction of particle size of dispersed phase in elastomer-plastic blends

In investigating the relationship between the particle size of the dispersed phase in a polymer blend and the physical properties of the resulting product, the effects of conditions of blending, viscosity difference, and volume fraction, etc., are usually observed and studied. This approach is uncertain since blending is a complex process. From a theoretical background similar to that of N. Tokita's, but using a different mathematical and experimental treatment, a complex factor composed of shear rate, apparent viscosity of the system, and volume fraction of the dispersed phase is proposed. This factor is found to provide a linear relation with the mean radius of dispersed particles as expressed by where R is the mean particle radius in the dispersed phase; S is shear rate of mixing;, V is apparent viscosity of the system; F is volume fraction of the dispersed phase; B is an experimental constant relating to breaking energy of the dispersed phase and interfacial tension; and A is also a constant relating to interfacial tension and the probability that a collision will result in a coalescence.     

Effect of the composition on the phase size in immiscible blends with the viscosity ratio close to unity

The influence of the composition and interfacial tension on the phase size in immiscible polymer blends with a viscosity ratio close to unity has been investigated with poly(methyl methacrylate)/poly(ethylene terephthalate) blends and data from various works. For all the blends considered, the dispersed particle diameter (d) is proportional to the interfacial tension of the system. When the dispersed‐phase content (?) is below 1%, there is minimal change of d with increasing ?. When ? is between 1 and 20%, d is proportional to ?^0.4. It seems that the processing conditions do not influence the morphology significantly for blend systems with a viscosity ratio close to unity.© 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 1791–1799, 2003     

Disprsion in high viscosity ratio polyolefin blends

The dispersion of polyethylene and polyropylene in a polypropylene matrix using a co‐rotating twin screw extruder has been investigated. Poymer pairs were selected to study the effect of viscosity ratio, defined as the viscosity of the minor component over that of the matrix, in the range 0.1 to 900. The dispersion quality was defined by determining the number of “gels,”i.e., large undispersed particles, present in thin films and by conventional microscopy techniques. The gel numbers were found to increase steadily with the viscoty ratio. It was also observed that particle size distributions in the high viscosity ratio blends was very broad, with particles as large as a hundred microns coexisting with much finer ones in the sub‐micron range. For a given polymer blend, the re‐processing was found to have and important effect on gel reduction. The effect of rotation speed, flow rate minor phase feeding position was aso investigated and is discussed in the paper.     

The effect of viscosity ratio on the phase inversion of polyamide 66/polypropylene blends

The rheological properties of the blend components are an important parameter in the formation of a blend morphology. The effect of viscosity ratio on the morphology of polyamide 66/polypropylene blends was studied, with primary attention to the phase-inversion behavior and the average particle size of the dispersed phase. The relationship between the mechanical properties and the phase-inversion composition was investigated as well. Noncompatibilized and compatibilized blends having five different viscosity ratios were prepared by twin-screw extrusion. Maleic anhydride-grafted polypropylene was used as the compatibilizer to increase the adhesion between the two polymers and to stabilize the blend morphology. Investigation of the morphology of the blends by microscopy (SEM and TEM) showed that the smaller the viscosity ration (η_PA/η_PP) the smaller was the polyamide 66 concentration at which the phase inversion took place and that polyamide 66 became the continuous phase. The results are in accord with the model of Jordhamo. The compatibilizer induced a sharp reduction of particle size, but did not have a major effect on the phaseinversion point. The tensile and impact properties of the compatibilized blends were found to correlate with the phase inversion. An improvement in the mechanical properties was observed when polyamide 66 provided the matrix phase. © 1994 John Wiley & Sons, Inc.     

Effects of the viscosity ratio on polyolefin ternary blends

Polyolefin binary and ternary blends were prepared from polypropylene (PP), an ethylene–α‐olefin copolymer (mPE), and high‐density polyethylene (HDPE) on the basis of the viscosity ratio of the dispersed phase to the continuous phase. In PP/mPE/HDPE blends, fibrils were observed when the dispersed‐phase (mPE/HDPE) viscosity was less than that of PP, or when the viscosity of mPE was less than that of PP, although the viscosity of mPE/HDPE was greater than that of PP. The notched impact strength and mechanical properties such as the yield strength, flexural modulus, and hardness of PP/mPE binary blends further increased with the addition of HDPE according to the type of HDPE. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 4027–4036, 2004     

The effect of the viscosity ratio of dispersed phase to matrix on the rheological,morphological, and mechanical properties of polymer blends containing a LCP

The effect of the viscosity ratio of the dispersed LCP phase to the polystyrene/poly(phenylene oxide) (PS/PPO) thermoplastic matrix on the rheological, morphological, and resultant mechanical properties of the LCP blends was investigated. The viscosity of PS/PPO is largely dependent on the blend composition, so that different levels of viscosity ratios of dispersed LCP phase to PS/PPO thermoplastic matrix are obtained by using PS/PPO premixtures of different blend ratios as a thermoplastic matrix. When the viscosity of the LCP dispersed phase is lower than that of the thermoplastic matrix, finely distributed fibril structure of LCP is obtained. Tensile modulus of injection molded specimens show a positive deviation from the additive rule when the viscosity ratio (η_LCP/η_matrix) is smaller than unity. These improvements in tensile modulus are attributed to the formation of finely distributed LCP fibrils. © 1996 John Wiley & Sons, Inc.     

PP/EHDPET共混体系熔体粘度对相转变的影响

以聚丙烯 (PP) /易水解聚酯 (EH DPET)共混体系为研究对象 ,测试了共混组分在不同加工温度与不同剪切速率下的熔体粘度。结果表明 ,加工温度与剪切速率的改变均会导致 PP与 EHDPET熔体粘度比的变化 ,进而影响到两组分的海 -岛结构构成。选择较高的加工温度及较低的剪切速率 ,可以使共混物 PP在高组成比时成为分散相。     

On the steady‐state drop size distribution in stirred vessels. Part I: Effect of dispersed phase viscosity

Previous studies on emulsification have used the maximum drop size (d_max) or Sauter mean diameter ( ) to investigate the effect of viscosity on the drop size distribution (DSD), however, these parameters fall short for highly polydispersed emulsions. In this investigation (Part I), the steady‐state DSD of dilute emulsions is studied using of silicon oils with viscosities varying across six orders of magnitude at different stirring speeds. Different emulsification regimes were identified; our modeling and analysis is centered on the intermediate viscosity range where interfacial cohesive stresses can be considered negligible and drop size increases with viscosity. The bimodal frequency distributions by volume were well described using two log‐normal density functions. © 2018 American Institute of Chemical Engineers AIChE J, 64: 3293–3302, 2018     

旋转圆环内分散气泡对液相表观黏度的影响

泡状液体广泛存在于化工、食品和生物医学等领域,深刻理解气泡对液相流变特性的影响对于产品质量改进和过程强化具有重要意义。文中以旋转流变仪作为物理模型,基于VOF和动网格相结合的方法,详细研究了分散气泡对液相表观黏度的影响。目前的研究发现:在相同气泡体积分数下,当毛细数较小时,由于表面张力,气泡几乎保持为球形,气泡的加入使流线扭曲,从而导致液相的相对黏度增大(即η_r1);然而,当毛细数较大时,气泡由圆形变为细长的椭圆形,并且沿最大法线方向气泡所占比例增加,气泡的加入使液相的相对黏度减小(即η_r1);而且对于相同毛细数的工况,体积分数越大,气泡对液相表观黏度的影响也越大。     

Effect of the viscosity ratio on the morphology and properties of PET/HDPE blends with and without compatibilization

The influence of the molecular weight of polyethylene on the morphology and mechanical properties of blends of high‐density polyethylene (HDPE) dispersed as droplets in a poly(ethylene terephthalate) (PET) matrix at various compositions was investigated. The difference of morphologies can be easily explained by the influence of the molecular weight on the viscosity ratio and therefore, on the critical capillary number. The compatibilizing efficiency of copolymers containing glycidyl methacrylate groups was also addressed in relation to their nature, the protocol for their drying and the molecular weight of the HDPE phase. The increase of adhesion between PET and HDPE was found to have a larger influence on tensile properties than the reduction of interfacial tension. The amount of compatibilizer needed for adhesion improvement depends on the interfacial area that is defined by both the interfacial tension and viscosity ratio of the components. A qualitative relation between the optimum amount of compatibilizer and the critical capillary number can be written. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Flow through a convergence. Part 2: Mixing of high viscosity ratio polymer blends

Dispersive mixing of high viscosity ratio blends was studied in a converging flow using a capillary rheometer equipped with dies having different entry profiles. Three inhomogeneous bimodal polyolefin blends, with stress‐dependent viscosity ratios ranging from 8 to 450, were used in this work. Such magnitudes of viscosity ratio indicate that the dispersed droplets can be mixed only in an elongational flow field. The mixing efficiency was found to be dependent on both the profile of the convergence and flow rate. At the lowest flow rates, the dispersive mixing efficiency was very low, but it increased with an increasing flow rate until a profile‐dependent maximum. This maximum mixing efficiency was observed prior to fracture of the matrix material, after which the efficiency decreased. Stress and deformation fields within different profiles were estimated by numerical simulation using the K‐BKZ equation, and the results were used to interpret experimental results. The dispersive mixing efficiency was found to be proportional to the maximum elongational stress within the converging section, and to the length of the region where the critical conditions for elastic fracture of droplet material were met. It is shown that the dispersive mixing mechanism in high viscosity ratio blends is mainly dictated by elastic fracture of the droplet, and hence is applicable over a wide range of polymer blending processes.     

Segmental mobility in the vicinity of Tg in PS/SBR blends: Nanodomain size prediction of the dispersed phase

The blends of polystyrene (PS) and styrene‐butadiene rubber (SBR) are melt‐blended at different ratios to form physical thermoplastic elastomers. This polymeric blend is expected to behave more or less similar to chemically synthesized block copolymers such as styrene‐butadiene block copolymers (SBS). In this study, mechanical and the thermomechanical properties of this blend are investigated and compared to those of SBS copolymer. As far as morphology is considered, the blend shows a two‐phase morphology with an interface, which shows very weak interactions. According to the observed morphology and the domain size of dispersed phase the blends are of good integrity. The mechanical properties of the blends confirm the integrity of the blend and effective interface stress transfer. The tensile and Izod impact properties of the blends shows improvements upon increase in SBR content of the blend. As SBR content augments the elongation at break increases, whereas tensile dissipated energy and impact resistance go through a maximum. Therefore, blend with SBR‐content in 60–75% range can be considered as preferred one. In a wide range of concentration a phase inversion was observed and T_g‐depression was detected also for the SBR phase. This T_g‐depression was correlated to the changes in dynamics of segments (segmental mobility) near the surfaces. Using the proposed relationships between T_g‐depression and the thickness of the thin films, it was tried to calculate domain size of SBR inclusions in PS matrix. A rough correlation between SBR domain sizes in SEM images and calculated thicknesses using T_g‐depression in thin films was found. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Tuning gradient microstructures in immiscible polymer blends by viscosity ratio

Bioinspired gradient microstructures provide an attractive template for functional materials with tailored properties. In this study, filaments with gradient microstructures are developed by melt-spinning of immiscible polymer blends. The distribution of the gradient morphology is shown to be controlled by the viscosity ratio of polymers as well as the geometry of the capillary die. Distinct microstructure gradients with long thin fibrils near the surface region and short large droplets near the center region of the filament, as well as the inverse pattern, are formed in systems with different viscosity ratios. The shear flow field in the capillary can elucidate the formation mechanisms of gradient morphologies during processing. The results demonstrate how the features of a gradient microstructure can be tailored by the design of capillary geometry and processing conditions. The viscosity ratio is then introduced as an adjusting tool to control the gradient morphology in a given processing setup. In consequence, this study provides novel design routes for achieving gradient morphologies in immiscible polymers. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 48165.     

Effect of viscosity ratio and processing conditions on the morphology of blends of liquid crystalline polymer and polypropylene

The effect of viscosity ratio and processing conditions on LCP/PP blend morphology was studied. The viscosity ratio (η_LCP/η_PP) was varied from 0.1 to 3.6 by using five different polypropylene grades as the matrix and two LCPs as the dispersed phase (20 wt %). The most spontaneous fiber formation was achieved when the viscosity ratio was between 0.5 and 1. In addition to shear forces, elongational forces are important in achieving a highly fibrillar structure and significant mechanical reinforcement. The lubricating effect induced by the low viscosity of LCP was most pronounced for the blends exhibiting a fibrillar morphology. The morphologies of blends produced by different mixing equipment differed only slightly. The greatest variation in the mixing efficiency was found for blends whose components had totally dissimilar melt viscosities. The slight differences in morphology due to melt blending in dissimilar equipment were decreased after injection molding, whereas the differences in morphology due to dissimilar viscosity ratios were still evident in the injection molded blends. Thus, the viscosity ratio at processing in the actual processing conditions is of great importance. © 1994 John Wiley & Sons, Inc.     

Effect of volume fraction and particle size on wall slip in flow of polymeric suspensions

For especially highly concentrated suspensions, slip at the wall is the controlling phenomenon of their rheological behavior. Upon correction for slip at the wall, concentrated suspensions were observed to have non‐Newtonian behavior. In this study, to determine the true rheological behavior of model concentrated suspensions, “multiple gap separation method” was applied using a parallel‐disk rheometer. The model suspensions studied were polymethyl methacrylate particles having average particle sizes, in the range of 37–231 μm, in hydroxyl terminated polybutadiene. The effects of particle size and solid particle volume fraction on the wall slip and the true viscosity of model concentrated suspensions were investigated. It is observed that, as the volume fraction of particles increased, the wall slip velocity and the viscosity corrected for slip effects also increased. In addition, for model suspensions in which the solid volume fraction was ≥81% of the maximum packing fraction, non‐Newtonian behavior was observed upon wall slip correction. On the other hand, as the particle size increased, the wall slip velocity was observed to increase and the true viscosity was observed to decrease. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 439–448, 2005     

Compatibilized iPP/aPS blends: The effect of the viscosity ratio of the components on the blends morphology

More than 25 PP/PS/SEP blends, where PP is isotactic polypropylene, PS is atactic polystyrene, and SEP is poly(styrene‐block‐ethylene‐co‐propylene), were prepared. The main objective of this study was to investigate the influence of PP/PS viscosity ratio, λ_TM, on the blends' morphology. It was shown that λ_TM strongly influenced not only the overall morphology of the blends, but also the morphology of SEP, which exhibited as many as five different types of structure when blended with PP and/or PS. SEP was found an efficient compatibilizer of PP/PS blends as it decreased the average particle size in all studied systems. An interesting “by‐product” of this work was the discovery of a brand‐new type of polymer morphology, which was called morel structure. The characteristic feature of the morel structure was PS matrix compartmentalized by SEP. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2236–2249, 2006     

Effect of viscosity variation with temperature on the compounding behavior of immiscible blends

Morphology development in the compounding of immiscible blends depends on a number of material properties and process conditions. In this work, different model blend systems are considered to outline the effects of the relative transition temperatures and viscosities of the blend components. We focus on the evolution of blend morphology, specifically phase continuity. A framework based on these factors is presented for analyzing the compounding behavior of immiscible blend systems. With the minor component at 10 wt%, it was found that phase inversion during compounding occurred in blends with a viscosity ratio of less than 0.2, independent of the relative transition temperatures. It was shown that in these constant mixer temperature runs, the torque trace was not a completely reliable indicator of phase inversion. When a temperature ramping program was used, the lower melting point component formed the continuous phase initially, independent of the viscosity ratio. Quantitative measures of the amount of minor component which was continuous at different mixing times were made using selective extraction in a Soxhlet apparatus. Results from compounding runs of polycarbonate/ polyethylene, an amorphous copolyester/polyethylene and polybutylene/polycaprolactone blends are presented.     

The effect of rubber particle size on the impact properties of high impact polystyrene (HIPS) blends

The impact fracture of nominally identical high impact polystyrene resins having different and well-characterized rubber particle size distributions is discussed. A numerical model for craze termination is presented and its predictions are compared with experimental data. An alternative explanation for the observed effect of particle size on fracture energy is considered.