| Abstract: | 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. |
