LAUSR

Suitable compatibilizers are essential to prepare immiscible polymer blends with stable co-continuous morphologies. From the thermodynamic point of view, such compatibilizer should not only reduce the interfacial tension, but also promote the formation of flat interface between different phases. Meanwhile, it must not hinder the coalescence of dispersed phase. Therefore, asymmetric structures are required for those block or graft copolymer compatibilizers. However, from the kinetic point of view, copolymers with asymmetric structures are prone to be dragged out from the interface and form micelles in one phase under the processing conditions, which will lose their compatibilization effects. The balance between such thermodynamic and kinetic factors remains unclear. In this paper, the relationship between the morphology of the compatibilized polystyrene/nylon 6/styrene-maleic anhydride copolymers (PS/PA6/SMA) immiscible polymer blends and the structures of the in-situ formed SMA-g-PA6 graft copolymers as well as the processing conditions are studied. Two kinds of SMA are used as compatibilizers: SMA28 (Mw = 110,000 g/mol, MAH content 28 wt.%) and SMA11 (Mw = 110,000 g/mol, MAH content 11 wt.%). After melt blending with PA6 into an internal mixer, the in-situ formed copolymer SMA28-g-PA6 has an average four PA6 side chains grafted on one SMA backbone, while that of SMA11-g-PA6 has only one PA6 side chain. Dissipative particle dynamics (DPD) simulation results indicate that both SMA28-g-PA6 copolymer and PS/PA6/SMA28 blends tend to form co-continuous structure, while SMA11-g-PA6 copolymer and PS/PA6/SMA11 blends form sea-island morphologies. However, these results are confirmed experimentally only at relatively low rotor speed of the internal mixer (60 rpm). When the rotor speed of the mixer is higher (105 rpm), sea-island morphologies are obtained in PS/PA6/SMA28 blends and co-continuous ones are found in PS/PA6/SMA11 systems. These results indicate that higher shear stress will favor to elongate the minor phase domains and form flat interfaces, which is benefit for the formation of co-continuous morphologies; meanwhile, high shear stress may pull the graft copolymers with asymmetric structures (SMA28-g-PA6) out from the interface of PS and PA6 and induce the formation of sea island morphologies. This article is protected by copyright. All rights reserved.