On the macro- and microphase separation of compatibilizers in immiscible polymer blends

Macro- and microphase separation of compatibilizing graft copolymers in melt-mixed polystyrene/polyamide-6 blends was studied by transmission electron microscopy and thermal analysis. Three different graft copolymers with main chains of polystyrene and side chains of poly(ethylene oxide) were used as additives at various concentrations. The polyamide-6 domain sizes decreased with increasing amounts of compatibilizing graft copolymers in the blends up to a saturation concentration, after which no further reduction was noted. Macrophase separation of the graft copolymers into discrete macrodomains 20-200 nm in size occurred at concentrations equal to or slightly lower than the saturation concentration. The macrodomains of the graft copolymers were microphase separated, and the sizes and shapes of the microdomains were found to largely depend on the graft copolymer structure and composition. As a consequence of microphase separation, poly(ethylene oxide) crystallinity was noted in blends with sufficiently high macrophase contents. Observations of a graft copolymer interphase between the polystyrene matrix and the polyamide-6 domains confirmed that the graft copolymer was present at the blend interfaces in some of the compatibilized blends. (C) 1996 John Wiley & Sons, Inc.