Shear field in the mold cavity of multimelt multi‐injection molding revealed by the morphology distribution of a model polymer blend

The morphology distribution of a model polymer blend, polystyrene (PS)/polyethylene (PE), molded by multimelt multi‐injection molding (MMMIM) process was studied by scanning electronic microscopy and polarizing light microscopy. An unusual double skin/core morphology was observed. The minor phase, PS, showed highly deformed morphology in both the skin layer near the mold wall and the core layer near the skin/core layer's interface. Meanwhile, in the regions that highly deformed PS phase showed, highly ordered cylindritic crystal structures of PE are also formed. As we all know the driving force and the basic prerequisite to deform the dispersed droplet and form the oriented crystal structure is the shear field. So an attempt was made to correlate the dispersed phase morphology, crystalline morphologies, and shear rate. The shear rate, estimated via the capillary number, across the thickness of the parts molded by MMMIM was bimodal. Even if the coalescence and relaxation of the dispersed phase during and after mold filling cannot be ignored, both the highly dispersed PS domains and the highly ordered crystal structure of PE showed in the regions with the maximum calculated shear rate, which is consistent with the generally accepted theories that strong shear flow is favorable to the formation of the oriented structures. POLYM. ENG. SCI., 54:2345–2353, 2014. © 2013 Society of Plastics Engineers     

Study on morphology of ternary polymer blends. II. Effect of composition

The composition effect on morphology of polypropylene/ethylene–propylene–diene terpolymer/polyethylene (PP/EPDM/PE) and polypropylene/ethylene–propylene–diene terpolymer/polystyrene (PP/EPDM/PS) ternary blends has been investigated. In all of the blends, polypropylene as the major phase was blended with two minor phases, that is, EPDM and PE or PS. From morphological studies using the SEM technique a core–shell morphology for PP/EPDM/PE and separated dispersed morphology for PP/EPDM/PS were observed. These results were found to be in agreement with the theoretical predictions. The composition of components affected only the size of dispersed phases and had no appreciable effect on the type of morphology. The size of each dispersed phase, whether it forms core or shell or disperses separately in matrix, can be related directly to its composition in the blend. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 1138–1146, 2001     

Morphology development of PC/PE blends during compounding in a twin-screw extruder

The morphological development of a polycarbonate/polyethylene (PC/PE) blend in a twin-screw extruder was studied using a scanning electron microscope (SEM). The effects of extrusion temperature, viscosity ratio (the ratio of the viscosity of the dispersed phase to that of the matrix), and the screw configuration on the morphology of the PC/PE blend during the extrusion were discussed in detail. It was found that the morphology of the dispersed particles and the interfacial adhesion between the dispersed phase and matrix were both influenced by the extrusion temperature. The dispersed phase had a spheroidal shape and a small size during the high temperature processing, and an irregular shape and a large size when it was processed at low temperature. The PC phase with a lower viscosity was easier to disperse and also to coalesce. Therefore, the deformation of the low-viscosity dispersed phase during the processing was more intense than that of the high-viscosity dispersed phase. By comparing the effects of the different screw configurations on the morphology development of the PC/PE blend, it was found that the melting and breaking up of the dispersed phase were mainly affected in the initial blending stages by the number of the kneading blocks. While a kneading block with a 90 degree staggering angle was used, the size of the dispersed particles decreased and the long fibers were shortened, the large particles were drawn by the additional kneading zone. Finally, all of these structures were completely changed to the short fibers. POLYM. ENG. SCI., 47:14–25, 2007. © 2006 Society of Plastics Engineers     

Investigation on particular phase morphology of immiscible polyamide 12 and polystyrene blends prepared via anionic ring‐opening polymerization

In this article, the particular phase morphology of immiscible polyamide 12/polystyrene (PA12/PS) blends prepared via in situ anionic ring‐opening polymerization of laurolactam (LL) in the presence of polystyrene (PS) was investigated. Scanning electron microscopy (SEM) and Fourier Transform infrared Spectroscopy (FTIR) were used to analyze the morphology of the blends. The results show that the PS is dispersed as small droplets in the continuous matrix of PA12 when PS content is 5 wt%. However, when the PS content is higher than 10 wt%, two particular phase morphologies appeared. Firstly, dispersed PS‐rich particles with the spherical inclusions of PA12 can be found when PS content is between 10 and 15 wt%. Then the phase inversion occurred (the phase morphology of the PA12/PS blends changed from the PS dispersed/PA12 matrix to PA12 dispersed/PS matrix system) when PS content is 20 wt% or higher, which is unusual for polymer blends prepared via conventional methods such as mixing, hydrolytic polycondensation and so on. The formation of this particular phase morphology development was simply elucidated via a phase inversion mechanism. Furthermore, the stability of the phase morphology of the PA12/PS blends after annealing at 230°C was also investigated via SEM. POLYM. ENG. SCI., 52:1831–1838, 2012. © 2012 Society of Plastics Engineers     

Morphology Dependent Double Yielding in Injection Molded Polycarbonate/Polyethylene Blend

Summary: Polycarbonate (PC)/polyethylene (PE) blend was injection molded at different molding temperatures. The morphological observation by scanning electronic microscope (SEM) indicated that the sample molded at 190 °C contained only uniformly dispersed spherical PC particles. The samples molded at 230 and 275 °C had a typical skin‐core structure, and there were many injection‐induced PC fibers in the subskin. While the sample molded at 190 °C had the usual stress‐strain behavior, the samples obtained at 230 and 275 °C showed apparently double yielding behavior. It was suggested that the double yielding points were morphology‐dependent. The first one was the result of the yielding of PE at low strain, and the second one was caused by the yielding of the PC fibers. Moreover, it is the frictional force in the interfaces between PC and PE that transferred the stress to the PC fibers, hence giving rise to the reinforcement of PE by PC.

Stress‐strain curves of PC/PE blends injection molded at various temperatures showing first (I) and second (II) yielding points.     

Investigation on particular morphology of immiscible polyamide 12/polystyrene blends

In this article, a particular phase morphology of immiscible polyamide 12/polystyrene (PA12/PS) blends prepared via in situ anionic ring-opening polymerization of Laurolactam (LL) in the presence of PS was investigated. SEM and FTIR were used to analyze the morphology of the blends. The results showed that PS is dispersed as small droplets in the continuous matrix of PA12 when PS content is less than 5 wt %. When the PS content is higher than 10 wt %, two particular phase morphologies appeared. First, dispersed PS-rich particles with the spherical inclusions of PA12 can be found when PS content is between 10 wt % and 15 wt %. Then, the phase inversion (the phase morphology of the PA12/PS blends changes from the PS dispersed/PA12 matrix to PA12 dispersed/PS matrix system) occurred when PS content is higher than 20 wt %, which is completely different from traditional polymer blends prepared by melt blending. The possible reason for the particular morphology development was illuminated through phase inversion mechanism. Furthermore, the stability of the phase morphologies of the PA12/PS blends was also investigated. SEM showed that the particular morphology is instability, and it will be changed upon annealing at 230°C for 30 min. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Evaluating PE/PLA interfacial tension using ternary immiscible polymer blends

Blending with ethylene-based flexible polymers such as polyethylene (PE) is one of the strategies to toughen poly(lactic acid) (PLA), an inherently brittle biodegradable plastic enjoying growing demands worldwide. Interfacial tension plays a crucial role in blend formulation. Yet several literature reports on the PE/PLA interfacial tension contradict each other, giving ~5 mN/m and ~11 mN/m. In this work, we demonstrate that the PE/PLA interfacial tension is at least 9 mN/m. We use a cocontinuous PE/polystyrene (PS)/PLA ternary blend. Scanning electron microscopy (SEM) revealed complete wetting morphology with PS phase separating PE and PLA phases in the ternary blend. In addition, the complete wetting behavior was maintained at a PS volume fraction as low as 3%. This morphology together with the Harkins equation, indicate that the PE/PLA interfacial tension is higher than 10.5 ± 1.4 mN/m at 180°C.     

Mechanical properties and creep resistance in polystyrene/polyethylene blends

Recycled plastics, predominantly high‐density polyethylene (PE), are being processed in the shape of dimension lumber and marketed as “plastic lumber.” One drawback to these products is their low creep resistance or high creep speed. The objective of this study was to examine the feasibility of reducing the creep speed of PE‐based products by blending the PE with a lower‐creep plastic, in this case polystyrene (PS). Various blends of PE and PS were prepared in either a laboratory extruder or a bowl mixer and then compression‐molded. The mechanical properties, creep behavior, morphology, and thermal properties of extruded and compression‐molded samples were determined. The modulus of elasticity of the extruded blends could be estimated by a weighted average of PS and PE, even in the absence of a compatibilizer. Processing strongly affected the morphology and mechanical properties of the blends. For 50% PS : 50% PE blends, the stress–strain curves of the extruded samples showed PE‐like behavior, whereas those from compression‐molded samples were brittle, PS‐like curves. Flexural strength was 50% higher in the extruded samples than in those from compression molding. The creep experiments were performed in three‐point bending. Creep speed was lower in 50% PS : 50% PE and 75% PS : 25% PE blends than in pure PS. Creep speed of 75% PS : 25% PE was lowest of all the extruded blends. PE formed the continuous phase even when the PS content was as high as 50 wt %. For a 75% PS : 25% PE blend, cocontinuous phases were observed in the machine direction. A ribbonlike PS‐dispersed phase was observed in the 25% PS : 75% PE and 50% PS : 50% PE samples. Blending low‐creep‐speed PS with high‐creep‐speed PE appeared to successfully improve the performance of the final composite. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 76: 1100–1108, 2000     

Compatibilization of a polyolefin blend through covalent and ionic coupling of grafted polypropylene and polyethylene. II. Morphology

The morphology of a polypropylene/polyethylene (PP/PE) blend and a maleic anhydride modified PP and PE (PPg/PEg) blend was studied. The initial morphology, at the extruder die, after the melt blending into a twin‐screw extruder, was first characterized. Then, the evolution of this initial morphology was followed after a injection molding operation, and during annealing in an oven at 200°C. The influence of the compatibilization of the blend by coupling reactions through covalent (with 1,12‐diaminododécane) and ionic reactions (with zinc acetate and sodium hydrogenocarbonate) was also investigated. At the extruder die, the viscosity ratio proved to be a determinant factor governing the dispersed phase diameter of the droplets, and as a second factor, the addition of small amounts of coupling‐agents together with (PPg/PEg) to (PP/PE) resulted in a decrease of the diameter of the droplets. The injection molding of these initial blends resulted in important coalescence and in an elongation of the dispersed phase. This was observed for the non compatibilized and also for some of the compatibilized blends. The ionic coupling showed a good stabilization of the morphology. Finally, the morphology of the non compatibilized blends was found to be instable when the material was annealed at 200°C. The average size of the dispersed phase increased. The coupling reactions delayed the occurrence of the coalescence about 5 min and limited its effects. The extent of the coarsening depended strongly on the composition of the blend and on the nature of the coupling. Still, the ionic agents appeared more effective. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 2237–2244, 2004     

The influence of the dispersed phase on the morphology,mechanical and thermal properties of PLA/PE‐LD and PLA/PE‐HD polymer blends and their nanocomposites with TiO2 and CaCO3

This research investigated the impact of different processing temperature (extrusion at 160°C and 180°C) and the influence of the TiO₂ and CaCO₃ fillers on morphology, mechanical, and thermal properties of polylactide (PLA) blended with low‐density polyethylene (PE‐LD) and high‐density polyethylene (PE‐HD) in 90/10 weight ratio. The impact of the particle size of the filler was also examined with the three types of TiO₂ filler. It has been shown that the different processing temperature has no significant impact on the morphology, mechanical, and thermal properties of PLA/PE‐LD 90/10 and PLA/PE‐HD 90/10 polymer blends. It has also been shown that better phase interaction is not the crucial factor for the improvement of the mechanical properties but the domain size distribution of the dispersed phase within the matrix and the dispersion of the filler are. Samples with a narrow size distribution of the dispersed phase domain (5 to 10 μm) with the higher portion of larger domains that are uniformly distributed within the polymer matrix showed best mechanical properties. POLYM. ENG. SCI., 59:1395–1408 2019. © 2019 Society of Plastics Engineers     

Effect of clay on immiscible morphology of poly(butylene terephthalate)/polyethylene blend nanocomposites

Polymer blend nanocomposites containing poly(butylene terephthalate) (PBT), polyethylene (PE), and organoclay were prepared by direct melt compounding. Their immiscible morphologies weree investigated using electronmicroscopy, X‐ray diffraction, and parallel plate rheometry. The PE domain sizes were reduced when the polar PBT phase was continuous (PBT/PE = 60/40) because the clay tactoids effectively prevented the coalescence of the dispersed PE domains. However, when the PBT component presented domains dispersed in the rich PE matrix (PBT/PE = 40/60), the addition of clay (>2 wt %) changed the phase morphology into a novel cocontinuous one, which was further confirmed by rheological measurements. The existence of clay tactoids led to a sharp enhancement in the viscosity of the PBT phase, changing the viscosity ratio between the PBT and PE phases remarkably, which may have promoted the phase inversion. As a result, clay had significant effects on the morphology of the polymer blend. © 2006 Wiley Periodicals Inc. J Appl Polym Sci 102: 3628–3633, 2006     

Co-continuous and encapsulated three phase morphologies in uncompatibilized and reactively compatibilized polyamide 6/polypropylene/polystyrene ternary blends using two reactive precursors

Phase morphology development in ternary uncompatibilized and reactively compatibilized blends based on polyamide 6 (PA6), polypropylene (PP) and polystyrene (PS) has been investigated. Reactive compatibilization of the blends has been performed using two reactive precursors; maleic anhydride grafted polypropylene (PP-g-MA) and styrene maleic anhydride copolymer (SMA) for PA6/PP and PA6/PS pairs, respectively. For comparison purposes, uncompatibilized and reactively compatibilized PA6/PP and PA6/PS binary blends, were first investigated. All the blends were melt-blended using a co-rotating twin-screw extruder. The phase morphology investigated using scanning electron microscope (SEM) and selective solvent extraction tests revealed that PA6/PP/PS blends having a weight percent composition of 70/15/15 is constituted from polyamide 6 matrix in which are dispersed composite droplets of PP core encapsulated by PS phase. Whereas, a co-continuous three-phase morphology was formed in the blends having a composition of 40/30/30. This morphology has been significantly affected by the reactive compatibilization. In the compatibilized PA6/(PP/PP–MA)/(PS/SMA) blends, PA6 phase was no more continuous but gets finely dispersed in the PS continuous phase. The DSC measurements confirmed the dispersed character of the PA6 phase. Indeed, in the compatibilized PA6/(PP/PP–MA)/(PS/SMA) blends where the PA6 particle size was smaller than 1 μm, the bulk crystallization temperature of PA6 (188 °C) was completely suppressed and a new crystallization peak emerges at a lower temperature of 93 °C as a result of homogeneous nucleation of PA6.     

Morphologies and properties of polycarbonate/polyethylene in situ microfibrillar composites prepared through multistage stretching extrusion

The sheets of polycarbonate (PC)/polyethylene (PE) in situ microfibrillar composites are successfully prepared directly through multistage stretching extrusion with an assembly of laminating‐multiplying elements (LMEs) instead of the secondary processing. The morphological development of the PC dispersed phase in PE matrix with increasing the number of LMEs during multistage stretching extrusion investigated by scanning electron microscope shows that core‐skin structure of the microfibrillar PC/PE composites during multistage stretching extrusion with 4 LMEs is weakened, and the diameter of the PC microfibrils is relatively more uniform, indicating that the shear field in LMEs greatly affects the morphology of PC dispersed phase in PE matrix. The tensile, crystalline, melting, orientation and rheological behavior of the PC/PE microfibrillar composites are also investigated. The results show that the PC microfibrils are helpful to increase complex viscosity and yield stress of the PE/PC composites. In addition, it is found that the glass transition temperature of PC in PE matrix reduced with increasing the number of LMEs during dynamic rheological testing. It is coincided with the results of DSC analysis of the PC/PE composites. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40108.     

Influence of morphology on PTC effect for poly (ethylene-co-butyl acrylate)/nylon6 blends with multiwall carbon nanotubes dispersed at interface and in matrix

Multiwall carbon nanotubes (MWCNTs) filled poly (ethylene-co-butyl acrylate)/nylon6 (EBA/PA6) blends were prepared by melt-mixing method. MWCNTs were localized in PA6 phase and the percolation threshold was 6 wt%. A weak PTC (positive temperature coefficient) effect was observed. The method that EBA-g-MAH was first reacted with MWCNTs, and then blended with EBA/PA6 was employed to prepare EBA/PA6/EBA-g-MAH/MWCNTs composites. TEM results showed that MWCNTs were localized both at the interface and in PA6 phase, resulting in the sharp decrease of the percolation threshold. Influence of morphology on the PTC effect of EBA/PA6/EBA-g-MAH/MWCNTs composites was studied. In composites with dispersed PA6 phase, the conductive pathways were fabricated by the contact of dispersed PA6 phase and MWCNTs in PA6 phase. The melt of polyethylene segment crystals in EBA and PA6 phase interrupted the contact of dispersed phases and conductive network formed by MWCNTs in PA6 phase, resulting in the double PTC effect. For composites with dispersed EBA phase, although the conductive pathways were similar with the composites with dispersed PA6 phase, the single PTC effect was observed. And the PTC effect was attributed to the melt of PA6 phase. The conductive pathways of composites with co-continuous morphology were fabricated by MWCNTs at the interface and in continuous PA6 phase. Two strong and a weak PTC effect were observed. PTC effects appeared at the melting temperature of PA6 crystals, polyethylene segment crystals and viscous flow temperature of butyl acrylate units in EBA.     

Reactive processing of polyethylene and polyethylene–ethylene/propylene/dicyclopentadiene blends under static and dynamic conditions

Abstract

Dicumyl peroxide induced reactive melt processing of polyethylene (PE) in a shear mix at 170°C in the absence or presence of selected acrylic monomers (acrylic acid, ethyl acrylate, and butyl acrylate) has been studied. The acrylic graft copolymers of PE showed development of higher shear stress compared with the control PE when studied rheologically in a plate and cone viscometer at 160–190°C. All the modified PE products retained the pseudoplastic flow behaviour of PE. Measure of rupture shear parameters and of thixotropic and relaxation behaviour of the different modified PEs and of the control PE were also evaluated and compared. The observed effects and unexpected trends were analysed and interpreted.

The comparative effects of sulphur vulcanisation of polyethylene–ethylene/propylene/dicyclopentadiene terpolymer (PE–EPDM) blends by static and dynamic techniques were also studied using both a conventional curative system and a silane curative system. Rheometric studies indicated development of a co-continuous phase morphology for the 30/70 PE–EPDM blend. For a given blend, cured under given conditions, tensile strength and elongation at break at 25°C were higher for vulcanisates obtained statically than for those obtained dynamically, while the corresponding modulus values followed the opposite trend. The conventional curative usually cured at a higher rate. The property differences from static and dynamic vulcanisation are explained in the light of the differences in the developed morphology.     

Study on morphology of ternary polymer blends. I. Effects of melt viscosity and interfacial interaction

The morphology of some ternary blends was investigated. In all of the blends polypropylene, as the major phase, was blended with two different minor phases, ethylene–propylene–diene terpolymer (EPDM) or ethylene–propylene–rubber (EPR) as the first minor phase and high‐density polyethylene (HDPE) or polystyrene (PS) as the second minor phase. All the blends were investigated in a constant composition of 70/15/15 wt %. Theoretical models predict that the dispersed phase of a multiphase polymer blend will either form an encapsulation‐type phase morphology or phases will remain separately dispersed, depending on which morphology has the lower free energy or positive spreading coefficient. Interfacial interaction between phases was found to play a significant role in determining the type of morphology of these blend systems. A core–shell‐type morphology for HDPE encapsulated by rubber was obtained for PP/rubber/PE ternary blends, whereas PP/rubber/PS blends showed a separately dispersed type of morphology. These results were found to be in good agreement with the theoretical predictions. Steady‐state torque for each component was used to study the effect of melt viscosity ratio on the morphology of the blends. It was found that the torque ratios affect only the size of the dispersed phases and have no appreciable influence on the type of morphology. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 1129–1137, 2001     

Effect of viscosity in ternary polymer blends displaying partial wetting phenomena

Partial wetting in a ternary polymer blend is the thermodynamic state where all three phases meet at a three-phase line of contact. Pickering emulsions, where solid particles situate at the interface of two other phases is a classic example of this state. This paper studies the presence of partial wetting in PE/PP/PS and in PE/PP/PC ternary polymer blends and examines, in particular, the influence of polyethylene viscosity on PS droplet formation at the PE/PP interface. Quantitative analysis of PS droplet growth and coverage at the PE/PP interface during static annealing were obtained by image analysis. A new approach was established to estimate the co-continuous PE/PP coarsening rate and was found to be in agreement with previous studies. In this work it is shown that the polyethylene viscosity can be of significant importance in ternary partial wetting when the interfacial driving force for partial wetting is weak and viscosity directly affects the quantity and size of PS droplets at the interface during annealing. The equilibrium between droplet stability at the interface, as predicted by spreading theory, and the interfacial mobility generated by coarsening determines the PS droplet size and surface coverage at the PE/PP interface.A ternary PE/PP/PC system, which displays a strong partial wetting driving force, was also investigated. The morphology of the blend system studied demonstrated a clear dominance of partial wetting over complete wetting.     

Effect of mixing protocol on compatibilized polymer blend morphology

We investigated the effect of mixing protocol on the morphology of compatibilized polymer blends made with premade compatibilizer and reactively formed in‐situ compatibilizer in a custom‐built miniature mixer Alberta Polymer Asymmetric Minimixer (APAM). The compatibilized blends show a finer morphology than uncompatibilized blends if the polymers are mixed together in the dry state and then fed into the mixer. It is found that premelting one polymer, and premixing polymers and compatibilizer, both greatly affect the compatibilized blends' morphology. The effects are complex since the dispersed phase particle size and distribution of the compatibilized blends may be smaller or larger when compared with the uncompatibilized system, depending on the material's physical and chemical properties; for example, diblock molecular weight or the preference of copolymer to migrate to a particular phase can change the final morphology. Good mobility of the copolymer to reach the interface is crucial to obtain a finer morphology. Micelles are observed when a high molecular weight diblock copolymer P(S‐b‐MMA) is used for a PS/PMMA blend. Because of its enhanced mobility, no micelles are found for a low molecular weight diblock copolymer P(S‐b‐MMA) in a PS/PMMA blend. For PS/PE/P(S‐b‐E) blends, finer morphology is obtained when P(S‐b‐E) is first precompounded with PS. Because the block copolymer prefers the PE phase, if the P(S‐b‐E) block copolymer is compounded with PE first, some remains inside the PE phase and does not compatibilize the interface. In the case of reactive blend PSOX/PEMA, premelting and holding the polymers at high temperature for 5 min decreases final dispersed phase particle size; however, premelting and holding for 10 min coarsens the morphology. POLYM. ENG. SCI. 46:691–702, 2006. © 2006 Society of Plastics Engineers.     

Melt blending of linear low-density polyethylene and polystyrene in a Haake internal mixer. II. Morphology-processing relationships

A measure of the effective shear rate range for dispersive mixing in the Haake mixer has been developed, which is more representative of shearing conditions than that currently used. In addition, the effects of processing conditions, composition, and compatibilizer on linear low-density polyethylene and polystyrene (LLDPE/PS) blend morphology were studied. Fiber/stratified morphologies form with blends when the minor phase has low viscosity and is present at its higher concentration. The influence of the viscosity ratio on phase size was found to be a minor effect for mixtures having a low fraction of the dispersed phase (20% PS). The effect of shear intensity, however, was found to be more important at a low composition of the dispersed phase or in compatibilized blends. During Haake blending, an optimal time for adding compatibilizer to stabilize phase morphology was found to be when the final morphology of an incompatible blend had developed. Further studies have concluded that the addition of styrene–ethylene/butylene–styrene (SEBS) stabilized the blend morphology of LLDPE/PS more efficiently than styrene–ethylene/propylene (SEP) on different blending conditions and compositions. At high temperatures, the addition of SEP to a LLDPE/PS blend did not modify the dispersed phase size. On the other hand, SEBS stabilized the dispersion so that the final domain size is independent of composition. © 1995 John Wiley & Sons, Inc.     

Effect of addition of polyethylene on properties of polypropylene/ethylene–propylene rubber blends

Toughening of polypropylene was carried out by adding two types of ethylene-propylene rubber (EPR) having different ethylene content, and three commercial types of EPR containing high density polyethylene (PE). The concentration of EPR was varied from 0–30%. Globular morphology of the dispersed phase was observed at all concentrations. Average particle size of the dispersed phase (EPR) was about 2–4 μm with about 10% within the 0.5–1 μm range. Although most of the properties were not affected by the presence of polyethylene, high notched Izod impact strength was achieved only with samples containing PE. Melt flow rate, yield strength and modulus were found to decrease almost linearly with increasing elastomer concentration in the blend. Elongation at break was enhanced by the addition of EPR, particularly those containing PE. The contribution of PE to the properties was explained by the specific EPR/PE particle morphology (core-shell or interpenetrating) but the exact mechanism of toughening of PP with EPR in the presence of PE is not clear. © 1996 John Wiley & Sons, Inc.