Phase morphology development in immiscible PP/(PS/PPE) blends influence of the melt-viscosity ratio and blend composition

Role of Rheology in Morphology Development and Advanced Processing of Thermoplastic Polymer Materials: A Review

This review presents fundamental knowledge and recent advances pertaining to research on the role of rheology in polymer processing, highlights the knowledge gap between the function of rheology in various processing operations and the importance of rheology in the development, characterization, and assessment of the morphologies of polymeric materials, and offers ideas for enhancing the processabilities of polymeric materials in advanced processing operations. Rheology plays a crucial role in the morphological evolution of polymer blends and composites, influencing the type of morphology in the case of blends and the quality of dispersion in the cases of both blends and composites. The rheological characteristics of multiphase polymeric materials provide valuable information on the morphologies of these materials, thereby rendering rheology an important tool for morphological assessment. Although rheology extensively affects the processabilities of polymeric materials in all processing operations, this review focuses on the roles of rheology in film blowing, electrospinning, centrifugal jet spinning, and the three-dimensional printing of polymeric materials, which are advanced processing operations that have gained significant research interest. This review offers a comprehensive overview of the fundamentals of morphology development and the aforementioned processing techniques; moreover, it covers all vital aspects related to the tailoring of the rheological characteristics of polymeric materials for achieving superior morphologies and high processabilities of these materials in advanced processing operations. Thus, this article provides a direction for future advancements in polymer processing. Furthermore, the superiority of elongational flow over shear flow in enhancing the quality of dispersion in multiphase polymeric materials and the role of extensional rheology in the advanced processing operations of these materials, which have rarely been discussed in previous reviews, have been critically analyzed in this review. In summary, this article offers new insights into the use of rheology in material and product development during advanced polymer-processing operations.

Influence of Polymer Processing on the Double Electrical Percolation Threshold in PLA/PCL/GNP Nanocomposites

For the first time, the double electrical percolation threshold was obtained in polylactide (PLA)/polycaprolactone (PCL)/graphene nanoplatelet (GNP) composite systems, prepared by compression moulding and fused filament fabrication (FFF). Using scanning electron microscopy (SEM) and atomic force microscopy (AFM), the localisation of the GNP, as well as the morphology of PLA and PCL phases, were evaluated and correlated with the electrical conductivity results estimated by the four-point probe method electrical measurements. The solvent extraction method was used to confirm and quantify the co-continuity in these samples. At 10 wt.% of the GNP, compression-moulded samples possessed a wide co-continuity range, varying from PLA55/PCL45 to PLA70/PCL30. The best electrical conductivity results were found for compression-moulded and 3D-printed PLA65/PCL35/GNP that have the fully co-continuous structure, based on the experimental and theoretical findings. This composite owns the highest storage modulus and complex viscosity at low angular frequency range, according to the melt shear rheology. Moreover, it exhibited the highest char formation and polymers degrees of crystallinity after the thermal investigation by thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC), respectively. The effect of the GNP content, compression moulding time, and multiple twin-screw extrusion blending steps on the co-continuity were also evaluated. The results showed that increasing the GNP content decreased the continuity of the polymer phases. Therefore, this work concluded that polymer processing methods impact the electrical percolation threshold and that the 3D printing of polymer composites entails higher electrical resistance as compared to compression moulding.

Properties of Styrene-Maleic Anhydride Copolymer Compatibilized Polyamide 66/Poly (Phenylene Ether) Blends: Effect of Blend Ratio and Compatibilizer Content

Two different blend ratios of polyamide 66 (PA66) and poly (2,6-dimethyl-1,4-phenylene ether) (PPE) (60/40 and 40/60 w/w) were produced via melt mixing. A styrene-maleic anhydride copolymer (SMA) was utilized at various contents from 2.5-15 wt% to compatibilize the immiscible blend system. The influence of SMA content and blend ratio was investigated based on (thermo-) mechanical and morphological properties of the PA66/PPE blends. Correlations between the interaction of SMA with the blend partners were established. For 60/40 blends, a droplet-sea morphology was visualized by transmission electron microscopy, wherein no major changes were seen upon SMA addition. In the case of 40/60 blends, strong coalescence was found in the binary blend. Up to 5 wt% SMA, the coalescence was inhibited by the interfacial activity of SMA, whereas 10 wt% SMA initiated a disperse-to-co-continuous transition, which was completed at 15 wt% SMA. An enhancement of tensile properties was achieved for all blends possessing SMA, where the maximum concentration of 15 wt% resulted in the highest elongation at break and tensile strength values. The relative improvement of the tensile properties was higher with the PPE-rich blend (40/60) which was attributed to a partial emulsification of the PPE phases forming a bimodal PPE domain size distribution with nano-droplets in the range of 60-160 nm.

Morphology, Rheology and Crystallization in Relation to the Viscosity Ratio of Polystyrene/Polypropylene Polymer Blends

Microfibrillar and droplet morphology of polypropylene (PP) phase dispersed in polypropylene (PS) was fabricated by using melt-extrusion. This morphology was obtained by introducing isotactic PP (20 wt.%) with different viscosity in the PS matrix (80 wt.%). Furthermore, the rheological properties of the blend investigated as a function of the viscosity ratio K. The variations in blend morphology were related to crystallization, melting properties, and viscoelasticity. The blends with K >> 1 develop a fine morphology with PP microfibrils along the flow direction, while diameters of the dispersed PP droplets gradually increase with lower values of K = 1, or K << 1. Crystallinity of the prepared blends significantly decreases compared to neat PP, while the microfibrillar morphology induces homogeneous crystallization with small crystallites. This is reflected in a decrease of the crystallization temperature, small loss in the crystallinity, and lower melting temperature of the PS80/PP20 blend compared to neat PP. The storage moduli, loss moduli, and complex viscosity are highest for the microfibrillar morphology that presents retarded relaxation. The rheological properties are dominated by the dispersed phase (K > 1), or matrix (K < 1). The variation in blend properties with microfibrillar morphology can be clearly distinguished from heterogeneous blends containing PP droplets, providing an efficient tool to create a binary blend with unique properties.

Effect of Compatibilization on Biobased Rubber-Toughened Poly(trimethylene terephthalate): Miscibility, Morphology, and Mechanical Properties

Fabrication of partially biobased poly(trimethylene terephthalate) (PTT) elastomeric blends was done via melt processing. Both natural rubber (NR) and epoxidized NR (ENR) were investigated as impact modifiers at 40 wt % loading to avoid lowering the overall biobased content of the blend system below that of the PTT alone (35% renewable content), along with maleated polybutadiene rubber (MR) and dicumyl peroxide (DCP) as reactive compatibilizers. The compatibility of the blend components was investigated using contact angle, rheometry, and scanning electron microscopy (SEM). The interfacial tensions and work of adhesions indicated that ENR was more miscible than NR in the PTT blend system, which was corroborated by the higher shear viscosity of the ENR blends and strong shear thinning behavior. Additionally, the predictive modeling of viscosity ratios on the elastomer-thermoplastic morphology was found to match the SEM micrographs with the dispersed elastomeric phase within the PTT matrix. The SEM images of the blends also establish that both the compatibilizers reduced the rubber inclusions size, though DCP hampered the impact performance as compared to the MR. In the presence of the MR, there was an increased cross-linking and observed variation in the Fourier transform infrared peaks demonstrating chemical interactions between the maleic anhydride groups with the PTT that allowed for the impact strength to reach 137 J·m^-1 or 4.5 times that of the neat PTT, with the modulus of toughness increased by 82% and an elongation at yield of 50% because of the flexibility and amorphous nature of the rubber constituent.

Insight into the formation of a continuous sheath structure for the PS phase in tri-continuous PVDF/PS/HDPE blends

A hierarchical tri-continuous structure is formed and controlled in PVDF/PS/HDPE ternary blends. A very high level of PS continuity, about 80%, is achieved only with a PS volume composition as low as 11 vol%.

Optical properties of polycarbonate/styrene-co-acrylonitrile blends: effects of molecular weight of the matrix

In this paper, the effects of the molecular weight of a polycarbonate (PC) matrix on the phase morphology and optical properties of a PC/styrene-co-acrylonitrile (SAN) blend were investigated. A scanning electron microscope is used to analyze the phase morphology of the blends, and Mie scattering theory is used to analyze the changing laws of the optical properties of PC/SAN blends with the increasing of PC molecular weight. Results show that the average particle diameter is not strongly changed with different PC molecular weight because the values of the viscosity ratios are very close to each other. But it is obvious that the number of large particles gradually reduced while small particles (especially d<2  μm) significantly increased with the increasing of PC molecular weight. And the increase in small particles will result in an increase in backward scattering so the transmittance of PC/SAN blends decreases with the increase of PC molecular weight. However, the balance of the scattering coefficients and the number concentration of particles eventually lead to the haze of the blends being very close, despite having different PC molecular weights. Meanwhile, the photographs of scattering patterns indicate that the PC/SAN blends whose component weight ratios are fixed at 70:30 have excellent antiglare properties, despite the changes in molecular weight of the PC matrix.

Effect of Blend Ratio on Phase Morphology and Mechanical Properties of High Density Polyethylene and Poly (Butylene Succinate) Blend

In this work, the effect of HDPE and PBS blend ratio on mechanical properties and phase morphology of the blend was investigated. HDPE/PBS blends were prepared at HDPE content of 20, 30, and 40 wt.% via melt mixing process and then molded using an injection machine. HDPE/PBS blend was an immiscible blend with a type of dispersed in matrix morphology and coalescence phase morphology depending on HDPE content. The blend morphology of 20 wt.% HDPE/PBS blend was a type of spherical domain dispersed in the PBS matrix. As increase HDPE content, the dispersed HDPE particles became larger and the shape turned into worm-like and elongated structure. In addition, at 40 wt.% HDPE, coalescence phase morphology was obtained. It was found that the PBS blends containing 30-40 wt.% HDPE did not show yield point; they exhibited brittle failure behavior. For tensile properties, yield strength and stress at break of HDPE/PBS blend gradually decreased with increasing HDPE content. However, addition of HDPE into PBS matrix resulted in an increase of Youngs modulus of the PBS blend. Impact strength of the blends was much lower than that of neat PBS but the impact strength of the blend insignificant changed with 30-40 wt.% HDPE comparing to that with 20 wt.% HDPE.

Morphology development and size control of poly(trimethylene terephthalate) nanofibers prepared from poly(trimethylene terephthalate)/cellulose acetate butyrate in situ fibrillar composites

Formation of nano-fibrillar composite structures provides an effective method for preparing thermoplastic nanofibers. By mixing two immiscible thermoplastic polymers in a twin screw extruder, poly(trimethylene terephthalate) (PTT) formed nano-fibrillar morphology in cellulose acetate butyrate (CAB) matrix, and then PTT nanofibers were obtained from PTT/CAB in situ fibrillar composites after removing the matrix phase of CAB. Blend ratio, shear rate, and draw ratio were three important parameters in the extrusion process, which could affect the shape and size of nanofibers. By varying the process conditions, average diameter of PTT nanofibers could be controlled in the range of 80-400 nm. Besides this, the mechanism of nano-fibrillar formation in PTT/CAB blends was also studied by collecting samples at different stages in the extruder. The morphology developmental trends of PTT dispersed phase with different blend ratios were nearly the same. From initial to metaphase and later phase development, the PTT dispersed component undergo the formation of sheets, holes, and network structures, then the size reduction and formation of nanofibers.

Foaming of an Immiscible Blend System Using Organic Liquids as Blowing Agents

Foaming of blend systems is a promising approach to develop cellular materials with a set of desired properties. However, foaming of blend systems is not only a chance but also a challenge, as different polymers have to be foamed at the same foaming conditions. The best conditions during foaming are individual to each polymer and influence the obtained cellular structure. In immiscible polymer blends like poly(2,6-dimethyl-1,4-phenylene ether) (PPE) and poly(styrene-co-acrylonitrile) (SAN) the differences in glass-transition temperature (Tg) and viscosity are vast and can inhibit the foaming of the blend system. In order to minimize the above-mentioned difference in Tg and viscosity, one approach is to choose a blowing agent, which shows a selective solubility in one polymer phase, working as a selective plasticizer. The aim of the present study is to evaluate systematically the foaming behavior of immiscible PPE/SAN blend systems using ethanol and n-pentane as blowing agents. Mass uptake of ethanol and n-pentane in the PPE/SAN-blends as function of the blend composition is measured, offering a selective solubility of ethanol in SAN, while n-pentane shows a high affinity to PPE. The plasticizing effect on the blend phases PPE and SAN is theoretically estimated using the Chow-equation and the WLF-equation. After foaming the blowing agent saturated blend samples in an oil-bath at different temperatures, the density reduction and the cellular structures are analyzed and correlated to the blend morphology, the blowing agent solubility in the blend phase, the rheological properties and the glass transition temperature of the nonsaturated and saturated blend phases.