Historical Perspective of Advances in the Science and Technology of Polymer Blends

Renormalized one-loop theory of correlations in disperse polymer blends

Polymer blends are critical in many commercial products and industrial processes and their phase behavior is therefore of paramount importance. In most circumstances, such blends are formulated with samples of high dispersity, which have generally only been studied at the mean-field level. Here, we extend the renormalized one-loop theory of concentration fluctuations to account for blends of disperse polymers. Analyzing the short and long length-scale fluctuations in a consistent manner, various measures of polymer molecular weight and dispersity arise naturally in the free energy. Thermodynamic analysis in terms of moments of the molecular weight distribution(s) provides exact results for the inverse susceptibility and demonstrates that the theory is not formally renormalizable. However, physically motivated approximations allow for an "effective" renormalization, yielding (1) an effective interaction parameter, χe, which depends directly on the sample dispersities (i.e., Mw/Mn) and leaves the form of the mean-field spinodal unchanged, and (2) an apparent interaction parameter χa that depends on higher-order dispersity indices, for instance Mz/Mw, and characterizes the true limits of blend stability accounting for long-range off-critical fluctuations. We demonstrate the importance of dispersity on several example systems, including both "toy" models that may be realized in computer simulation and more realistic industrially relevant blends. We find that the effects of long-range fluctuations are particularly prominent in blends where the component dispersities are mismatched, especially when there is a small quantity of the high-dispersity species. This can be understood as a consequence of the shift in the critical concentration(s) from the monodisperse value(s).

On the Mechanical, Thermal, and Rheological Properties of Polyethylene/Ultra-High Molecular Weight Polypropylene Blends

The novel ultra-high molecular weight polypropylene (UHMWPP) as a dispersed component was melt blended with conventional high-density polyethylene (PE) and maleic anhydride grafted-polyethylene (mPE) in different proportions through a kneader. Ultra-high molecular weight polypropylene is a high-performance polymer material that has excellent mechanical properties and toughness compared to other polymers. Mechanical, thermal, and rheological properties were presented for various UHMWPP loadings, and correlations between mechanical and rheological properties were examined. Optimal comprehensive mechanical properties are achieved when the UHMWPP content reaches approximately 50 wt%, although the elongation properties do not match those of pure PE or mPE. However, it is worth noting that the elongation properties of these blends did not match those of PE or mPE. Particularly, for the PE/UHMWPP blends, a significant drop in tensile strength was observed as the UHMWPP content decreased (from 30.24 MPa for P50U50 to 13.12 MPa for P90U10). In contrast, the mPE/UHMWPP blends demonstrated only minimal changes in tensile strength (ranging from 29 MPa for mP50U50 to 24.64 MPa for mP90U10) as UHMWPP content varied. The storage modulus of the PE/UHMWPP blends increased drastically with the UHMWPP content due to the UHMWPP chain entanglements and rigidity. Additionally, we noted a substantial reduction in the melt index of the blend system when the UHMWPP content exceeded 10% by weight.

Dual Transient Networks of Polymer and Micellar Chains: Structure and Viscoelastic Synergy

Dual transient networks were prepared by mixing highly charged long wormlike micelles of surfactants with polysaccharide chains of hydroxypropyl guar above the entanglement concentration for each of the components. The wormlike micelles were composed of two oppositely charged surfactants potassium oleate and n-octyltrimethylammonium bromide with a large excess of anionic surfactant. The system is macroscopically homogeneous over a wide range of polymer and surfactant concentrations, which is attributed to a stabilizing effect of surfactants counterions that try to occupy as much volume as possible in order to gain in translational entropy. At the same time, by small-angle neutron scattering (SANS) combined with ultrasmall-angle neutron scattering (USANS), a microphase separation with the formation of polymer-rich and surfactant-rich domains was detected. Rheological studies in the linear viscoelastic regime revealed a synergistic 180-fold enhancement of viscosity and 65-fold increase of the longest relaxation time in comparison with the individual components. This effect was attributed to the local increase in concentration of both components trying to avoid contact with each other, which makes the micelles longer and increases the number of intermicellar and interpolymer entanglements. The enhanced rheological properties of this novel system based on industrially important polymer hold great potential for applications in personal care products, oil recovery and many other fields.

Blending as a Strategy to Attain Chiro-Optically Activity Polymers

Two copolymers, one containing a chiral center and another without any asymmetric site are studied regarding their chiro-optical properties. The pure polymers do not show any signal of chiro-optical activity, only a smooth line is observed in the circular dichroism spectra, even for the chiral material. However, blends containing the achiral one as a major component show striking chiro-optical activity, originating by stable supramolecular structures whose size and shape remain unchanged, regardless of the blend composition. Only the number of such structures (composed by the chiral one), vary with blend composition. The results suggest that working with supramolecular morphology can be an important strategy to attain chiro-optical active polymers.

Relationship between the Processing, Structure, and Properties of Microfibrillar Composites

The relationship between processing, morphology, and properties of polymeric materials has been the subject of numerous studies of academic and industrial research. Finding an answer to this question might result in guidelines on how to design polymeric materials. Microfibrillar composites (MFCs) are an interesting class of polymer-polymer composites. The advantage of the MFC concept lies in developing in situ microfibrils by which a perfect homogeneous distribution of the reinforcement in the matrix can be achieved. Their potentially excellent mechanical properties are strongly dependent on the aspect ratio of the fibrils, which is developed through a three-stage production process: melt blending, fibrillation, and isotropization. During melt blending, the polymers undergo different morphological changes, such as a breakup and coalescence of the droplets, which play a crucial role in defining the microstructure. During processing, various parameters may affect the morphology of the MFCs, which must be taken into account. Besides the processing parameters, the microstructure of the composite is dependent on the composition ratio of the blend and viscosity of the components, as well as the dispersion and distribution of the microfibrils. The objective here is to outline this importance and bring together an overview of the processing-structure-property relationship for MFCs.

Renewable and Tough Poly(l-lactic acid)/Polyurethane Blends Prepared by Dynamic Vulcanization

Melt blending of homopolymers is an effective way to achieve an attractive combination of polymer properties. Dynamic vulcanization of fatty-acid-based polyester polyol with glycerol and poly(l-lactic acid) (PLLA) in the presence of hexamethylene diisocyanate (HDI) was performed with the aim of toughening PLLA. The dynamic vulcanization in an internal mixer led to the formation of a PLLA/PU biobased blend. Melt torque, Fourier transform infrared (FTIR), and gel fraction analysis demonstrated the successful formation of cross-linked polyurethane (PU) inside the PLLA matrix. Scanning electron microscopy (SEM) analysis showed that the PLLA/PU blends exhibit a sea-island morphology. Gel fraction analysis revealed that a rubbery phase was formed inside the PLLA matrix, which was insoluble in chloroform. FTIR analysis of the insoluble part shows the appearance of an absorption band centered at 1758 cm-1, related to the crystalline carbonyl vibration of the PLLA component, thus suggesting the partial involvement of PLLA chains in the cross-linking reaction. The overall content of the PU phase in the blends significantly affected the mechanical properties, thermal stability, and crystallization behavior of the materials. The overall crystallization rate of PLLA was noticeably decreased by the incorporation of PU. At the same time, polarized light optical microscopy (PLOM) analysis revealed that the presence of the PU rubbery phase inside the PLLA matrix promoted PLLA nucleation. With the formation of the PU network, the impact strength showed a remarkable increase while Young's modulus correspondingly decreased. The blends showed slightly reduced thermal stability compared to the neat PLLA.

Bio-Based PBT-DLA Copolyester as an Alternative Compatibilizer of PP/PBT Blends

The aim of this work was to assess whether synthesized random copolyester, poly(butylene terephthalate-r-butylene dilinoleate) (PBT–DLA), containing bio-based components, can effectively compatibilize polypropylene/poly(butylene terephthalate) (PP/PBT) blends. For comparison, a commercial petrochemical triblock copolymer, poly(styrene-b-ethylene/butylene-b-styrene) (SEBS) was used. The chemical structure and block distribution of PBT–DLA was determined using nuclear magnetic resonance spectroscopy and gel permeation chromatography. PP/PBT blends with different mass ratios were prepared via twin-screw extrusion with 5 wt% of each compatibilizer. Thermogravimetric analysis, differential scanning calorimetry, and dynamic mechanical analysis were used to assess changes in phase structure of PP/PBT blends. Static tensile testing demonstrated marked improvement in elongation at break, to ~18% and ~21% for PBT–DLA and SEBS, respectively. Importantly, the morphology of PP/PBT blends compatibilized with PBT–DLA copolymer showed that it is able to act as interphase modifier, being preferentially located at the interface. Therefore, we conclude that by using polycondensation and monomers from renewable resources, it is possible to obtain copolymers that efficiently modify blend miscibility, offering an alternative to widely used, rubber-like petrochemical styrene compatibilizers.

Amphiphilic Janus nanosheets by grafting reactive rubber brushes for reinforced rubber materials

An amphiphilic Janus nanosheet with different reactive rubber brushes on two opposite sides can simultaneously strengthen and toughen rubber blends.

High transparent mid-infrared silicon "window" decorated with amorphous photonic structures fabricated by facile phase separation

High transparency in the infrared (IR) region is desirable for most common IR materials and devices, due to their high interfacial reflectance, resulting from the high refractive indices of constituent substances. Herein, a new strategy, with using phase-separated polystyrene (PS)/polymethylmethacrylate (PMMA) blends as masks, is proposed to fabricate subwavelength structures for Si with significantly enhanced mid-IR transmission. Maximum transmittance approaching to 70% and 90% are achieved with single and double- side structured Si respectively. The fabricated subwavelength structures are short-range ordered amorphous photonic structures (APSs). By using different spin-coating speeds and molar ratios of PS to PMMA and by adjusting the etching duration time, tunable enhanced transmission are also obtained. The good performance of high transmission is confirmed by mid-IR thermal imaging experiments. Furthermore, the enhanced transmission is effective over a wide range of incident angles up to 50° and well maintained at high temperatures up to 600 °C.

Investigation of phase separated polyimide blend films containing boron nitride using FTIR imaging

Immiscible aromatic polyimide (PI) blend films and a PI blend film incorporated with thermally conductive boron nitride (BN) were prepared, and their phase separation behaviors were examined by optical microscopy and FTIR imaging. The 2,2'-bis(trifluoromethyl)benzidine (TFMB)-containing and 4,4'-thiodianiline (TDA)-containing aromatic PI blend films and a PI blend/BN composite film show two clearly separated regions; one region is the TFMB-rich phase, and the other region is the TDA-rich phase. The introduction of BN induces morphological changes in the immiscible aromatic PI blend film without altering the composition of either domain. In particular, the BN is selectively incorporated into the TDA-rich phase in this study.

Self-Forming Interlocking Interfaces on the Immiscible Polymer Bilayers via Gelation-Mediated Phase Separation

Gelation-mediated phase separation is applied to prepare immiscible polymer bilayer films with an interlocking interface structure. Polymer systems consisting of copolymer of urea and polydimethylsiloxane and epoxy are selected to demonstrate the feasibility. When the epoxy fraction exceeds 25 wt%, well-defined bilayer structures self-form by a one-pot casting method in which the phase separation state is fixed by an evaporation-induced gelation. Microscopy studies of the resulting bilayers clearly reveal that interlocking structures form during the bilayer films construct. The interlocking structures lead to an enhanced interfacial adhesion and higher fracture energy. The current strategy might offer a facile way to in situ create an interlocking interface between immiscible polymer systems.

Poly(lactic acid) blends in biomedical applications

Poly(lactic acid) (PLA) has become a "material of choice" in biomedical applications for its ability to fulfill complex needs that typically include properties such as biocompatibility, biodegradability, mechanical strength, and processability. Despite the advantages of pure PLA in a wider spectrum of applications, it is limited by its hydrophobicity, low impact toughness, and slow degradation rate. Blending PLA with other polymers offers a convenient option to enhance its properties or generate novel properties for target applications without the need to develop new materials. PLA blends with different natural and synthetic polymers have been developed by solvent and melt blending techniques and further processed based on end-use applications. A variety of PLA blends has been explored for biomedical applications such as drug delivery, implants, sutures, and tissue engineering. This review discusses the opportunities for PLA blends in the biomedical arena, including the overview of blending and postblend processing techniques and the applications of PLA blends currently in use and under development.

Nanoparticle induced miscibility in LCST polymer blends: critically assessing the enthalpic and entropic effects

The use of polymer blends widened the possibility of creating materials with multilayered architectures.