From polymer blends to in situ polymer/polymer composites:: Morphology control and mechanical properties

In situ polymer/polymer short fiber composites were generated by a two-step process. In the first step, a polyamide (PA) dispersed phase is blended with a polypropylene (PP) matrix in a twin-screw extruder at a temperature at which both polymers are in molten state. The extrudate was then stretched at the die exit to generate long and thin fibers of PA in the PP matrix well oriented in the direction of flow. Adhesion between the phases was promoted by addition of PP grafted with maleic anhydride (PP-g-MA). During the second step, the chopped extrudates were molded by injection or compression molding at a temperature at which PA in the form of fibers is in the solid state and the PP matrix is molten. The control of the formation of such ultrafine fibers was obtained by quantitative analyses for the deformation of the minor PA-phase during twin-screw extrusion and stretching at the exit of the die that involve both shear and extensional flows. Morphology and mechanical properties of such polymer/polymer composites were compared to equivalent blends with dispersed spherical particles-type morphology prepared in a batch mixer device.