Coarsening in molten quiescent polymer blends: The role of the initial morphology

Closely Packed Conductive Droplets with Polygon-Like Patterns Confined at the Interface in Ternary Polymer Blends

This work reports on the formation of closely packed conductive droplets demonstrating polygon-like patterns at the interface in partially wetted ternary polymer systems prepared by melt blending and annealing treatment. The low-density polyethylene/poly(ether-block-amide)/poly(butylene-adipate-co-terephthalate) (LDPE/PEBA/PBAT) blend showed an intermediate partial wetting tendency where the interfacially localized conductive PEBA phase developed connected structure after blending but transformed into dispersed droplets upon annealing. The coalescence of the PEBA droplets appeared to be initiated by the Rayleigh-type instability in the thin PBAT film separating PEBA. However, the intrinsic coalescence rate of the PEBA droplets was very low due to the low interfacial tension of PEBA/PBAT. This slow coalescence of PEBA combined with the fast reduction in the interfacial area during annealing and the intermediate partial wetting state of the LDPE/PEBA/PBAT system resulted in a unique morphology of closely packed PEBA droplets with polygon-like patterns at a volume fraction of 50/10/40. Two other representative ternary polymer blends, LDPE/PEBA/polypropylene (PP) and compatibilized LDPE/PEBA/polystyrene (PS), with strong and weak partial wetting morphologies were also examined to highlight the mechanism for the morphology development in the LDPE/PEBA/PBAT blend.

Effect of phase coarsening under melt annealing on the electrical performance of polymer composites with a double percolation structure

The effect of phase coarsening on the evolution of the carbon black (CB) nanoparticle network under quiescent melt annealing and the electrical performance of polypropylene/polystyrene/carbon black (PP/PS/CB) composites with a double percolation structure was investigated. The results showed that when the CB content is low, the coarsening process of PP/PS/CB blends can be divided into two stages. In the first stage, the coarsening rate is fast before the formation of the CB nanoparticle network, and after annealing for a certain time, the evolution of the co-continuous morphology can drive the CB nanoparticles to self-assemble into a complete nanoparticle network. In the second stage, the coarsening rate is slow after the formation of the CB nanoparticle network. When the CB content is high, the CB nanoparticle network can be maintained throughout the whole annealing process, so that the conductivity and morphology of the PP/PS/CB composites are stable. Moreover, the electrical conductivity of the PP/PS/CB composites greatly increases after annealing for a certain time, and a percolation threshold as low as 0.07 vol% can be obtained. These results reveal the relationship between the evolution of the morphology and the conductivity in the conductive polymer composites with a double percolation structure, and provide a more in-depth and comprehensive understanding of the double percolation structure.

Partial to complete wetting transitions in immiscible ternary blends with PLA: the influence of interfacial confinement

In this study it is shown that the three different intermediate phases in melt blended ternary PLA/PHBV/PBS, PLA/PBAT/PE and PLA/PE/PBAT systems all demonstrate partial wetting, but have very different wetting behaviors as a function of composition and annealing. The interfacial tension of the various components, their spreading coefficients and the contact angles of the confined partially wet droplets at the interface are examined in detail. A wetting transition from partially wet droplets to a complete layer at the interface is observed for both PHBV and PBAT by increasing the concentration and also by annealing. In contrast, in PLA/PE/PBAT, the partially wet droplets of PE at the interface of PLA/PBAT coalesce and grow in size, but remain partially wet even at a high PE concentration of 20% and after 30 min of quiescent annealing. The dewetting speed of the intermediate phase is found to be the principal factor controlling these wetting transitions. This work shows the significant potential for controlled wetting and structuring in ternary polymer systems.

Modification of linear prepolymers to tailor heterogeneous network formation through photo-initiated Polymerization-Induced Phase Separation

Polymerization-induced phase separation (PIPS) was studied in ambient photopolymerizations of triethylene glycol dimethacrylate (TEGDMA) modified by poly(methyl methacrylate) (PMMA). The molecular weight of PMMA and the rate of network formation (through incident UV-irradiation) were varied to influence both the promotion of phase separation through increases in overall free energy, as well as the extent to which phase development occurs during polymerization through diffusion prior to network gelation. The overall free energy of the polymerizing system increases with PMMA molecular weight, such that PIPS is promoted thermodynamically at low loading levels (5 wt%) of a higher molecular weight PMMA (120 kDa), while a higher loading level (20 wt%) is needed to induce PIPS with lower PMMA molecular weight (11 kDa), and phase separation was not promoted at any loading level tested of the lowest molecular weight PMMA (1 kDa). Due to these differences in overall free energy, systems modified by PMMA (11 kDa) underwent phase separation via Nucleation and Growth, and systems modified by PMMA (120 kDa), followed the Spinodal Decomposition mechanism. Despite differences in phase structure, all materials form a continuous phase rich in TEGDMA homopolymer. At high irradiation intensity (Io=20mW/cm2), the rate of network formation prohibited significant phase separation, even when thermodynamically preferred. A staged curing approach, which utilizes low intensity irradiation (Io=300µW/cm2) for the first ~50% of reaction to allow phase separation via diffusion, followed by a high intensity flood-cure to achieve a high degree of conversion, was employed to form phase-separated networks with reduced polymerization stress yet equivalent final conversion and modulus.

Accessing photo-based morphological control in phase-separated, cross-linked networks through delayed gelation

This work presents an approach to extend the period for phase separation, independent of temperature, in ambient phase-separating photopolymerizations based on the copolymerization of structurally similar mono- and di-vinyl monomers. Copolymer resins composed of triethylene glycol dimethacrylate (TEGDMA) and ethylene glycol methyl ether methacrylate (EGMEMA) were modified with a thermoplastic prepolymer, poly(butyl methacrylate). With increasing EGMEMA modification into the bulk TEGDMA resin, there is a decrease in the initial reaction rate, which increases the time for development of compositionally different phases prior to network gelation. The period between phase separation and gelation was probed through optical and rheological measurements, and it was extended from 22 s in a TEGDMA resin to 69 s in a TEGDMA:EGMEMA copolymer, allowing these materials to be processed under a wide range of UV-irradiation intensities (300 µW cm^-2 - 100 mW cm^-2), which provided an additional degree of control over the resulting phase separated domain size and morphology.

Suppressing phase coarsening in immiscible polymer blends using nano-silica particles located at the interface

Coalescence suppressing effect of nanoparticles at the interface of polymer blends.

Suppression of phase coarsening in immiscible, co-continuous polymer blends under high temperature quiescent annealing

The properties of polymer blends greatly depend on the morphologies formed during processing, and the thermodynamic non-equilibrium nature of most polymer blends makes it important to maintain the morphology stability to ensure the performance stability of structural materials. Herein, the phase coarsening of co-continuous, immiscible polyamide 6 (PA6)-acrylonitrile-butadiene-styrene (ABS) blends in the melt state was studied and the effect of introduction of nano-silica particles on the stability of the phase morphology was examined. It was found that the PA6-ABS (50/50 w) blend maintained the co-continuous morphology but coarsened severely upon annealing at 230 °C. The coarsening process could be divided into two stages: a fast coarsening process at the initial stage of annealing and a second coarsening process with a relatively slow coarsening rate later. The reduction of the coarsening rate can be explained from the reduction of the global curvature of the interface. With the introduction of nano-silica, the composites also showed two stages of coarsening. However, the coarsening rate was significantly decreased and the phase morphology was stabilized. Rheological measurements indicated that a particle network structure was formed when the concentration of nano-silica particles was beyond 2 wt%. The particle network inhibited the movement of molecular chains and thus suppressed the coarsening process.

Effects of plasticization and shear stress on phase structure development and properties of soy protein blends

In this study, soy protein concentrate (SPC) was used as a plastic component to blend with poly(butylene adipate-co-terephthalate) (PBAT). Effects of SPC plasticization and blend composition on its deformation during mixing were studied in detail. Influence of using water as the major plasticizer and glycerol as the co-plasticizer on the deformation of the SPC phase during mixing was explored. The effect of shear stress, as affected by SPC loading level, on the phase structure of SPC in the blends was also investigated. Quantitative analysis of the aspect ratio of SPC particles was conducted by using ImageJ software, and an empirical model predicting the formation of percolated structure was applied. The experimental results and the model prediction showed a fairly good agreement. The experimental results and statistic analysis suggest that both SPC loading level and its water content prior to compounding had significant influences on development of the SPC phase structure and were correlated in determining the morphological structures of the resulting blends. Consequently, physical and mechanical properties of the blends greatly depended on the phase morphology and PBAT/SPC ratio of the blends.

Macroporous poly(l-lactide) of controlled pore size derived from the annealing of co-continuous polystyrene/poly(l-lactide) blends

A detailed study on the static annealing of co-continuous polystyrene/poly(L-lactide) (PLLA) blends is presented. The effects of temperature, time at temperature, viscosity of the phases and interfacial modification on the coarsening of the blend are discussed. In this paper, polystyrene and PLLA are blended at compositions of 50/50 and 60/40 to form co-continuous morphologies. These co-continuous morphologies are coarsened under quiescent annealing conditions, and the subsequent removal of the polystyrene phase leaves a macroporous PLLA structure. The microstructure is analyzed using three different techniques: the BET nitrogen adsorption technique, mercury intrusion porosimetry and SEM combined with image analysis. It is shown that static annealing can be used to generate a series of co-continuous networks with controlled pore sizes ranging from 1 to hundreds of microns. A non-linear pore size growth rate is observed for these systems due to the degradation of PLLA and this study indicates that controlled degradation can be used as an additional tool for morphology control. Compatibilized polystyrene/PLLA blends demonstrate significantly reduced coarsening effects due to the reduction of interfacial tension. The coarsening rate of the co-continuous structure was examined in terms of the pore size, R and this growth rate is discussed in terms of a previously proposed coarsening mechanism. This approach is a route towards the preparation of a macroporous PLLA structure with pore sizes in the range required for scaffolds for tissue regeneration.