Compatibilizing effects of block copolymer mixed with immiscible polymer blends by solid-state shear pulverization: stabilizing the dispersed phase to static coarsening

A continuous, industrially scalable process called solid-state shear pulverization (SSSP) leads to compatibilization of polystyrene (PS)/high-density polyethylene (HDPE) blends by addition of a commercially available styrene/ethylene–butylene/styrene (SEBS) triblock copolymer. Partial or full compatibilization is characterized by a reduction or elimination of coarsening of the dispersed-phase domains during high-temperature (190 °C), static annealing. In the case of a 90/10 wt% PS/HDPE blend, processing with 3.5 wt% SEBS block copolymer by SSSP yields a coarsening rate that is reduced by a factor of 10 (six) relative to a melt-mixed blend without copolymer (with 3.5 wt% SEBS block copolymer). Addition of 5.0 wt% SEBS block copolymer to the 90/10 wt% PS/HDPE blend during SSSP yields a reduction in coarsening rate by a factor of thirty relative to a melt-mixed blend without copolymer. With an 80/20 wt% PS/HDPE blend, pulverization with 10 wt% SEBS block copolymer yields cessation of coarsening when the average dispersed-phase domain diameter reaches 1.6–1.7 μm. The implications of these results for developing a new, technologically attractive method for achieving compatibilization of immiscible polymer blends are discussed.