Morphology development in polyethylene/polystyrene blends: the influence of processing conditions and interfacial modification

The influence of processing conditions and interfacial modification on the morphology evolution and the composition range within which fully co-continuous high density polyethylene/polystyrene blend structures can exist during blending in a single screw extruder was studied. Blends ranging from pure A to pure B component, with and without compatibilizer, were prepared under two different shear rates. It was found that high shear rates displaced the breakdown–coalescence balance of the dispersed nodules to the side of coalescence, narrowing the percolation domain and the critical composition for full co-continuity decreased with increasing shear rates. The addition of a tri-block compatibilizer induced the percolation threshold of the polystyrene phase to begin at lower percentages of polyethylene but the phase inversion point did not change. The experimental results are discussed in the light of various theoretical models. Copyright © 2005 Society of Chemical Industry