A composition-morphology map for particle-filled blends of immiscible thermoplastic polymers

Impact of particle arrays on phase separation composition patterns

We examine the symmetry-breaking effect of fixed constellations of particles on the surface-directed spinodal decomposition of binary blends in the presence of particles whose surfaces have a preferential affinity for one of the components. Our phase-field simulations indicate that the phase separation morphology in the presence of particle arrays can be tuned to have a continuous, droplet, lamellar, or hybrid morphology depending on the interparticle spacing, blend composition, and time. In particular, when the interparticle spacing is large compared to the spinodal wavelength, a transient target pattern composed of alternate rings of preferred and non-preferred phases emerges at early times, tending to adopt the symmetry of the particle configuration. We reveal that such target patterns stabilize for certain characteristic length, time, and composition scales characteristic of the pure phase-separating mixture. To illustrate the general range of phenomena exhibited by mixture-particle systems, we simulate the effects of single-particle, multi-particle, and cluster-particle systems having multiple geometrical configurations of the particle characteristic of pattern substrates on phase separation. Our simulations show that tailoring the particle configuration, or substrate pattern configuration, a relative fluid-particle composition should allow the desirable control of the phase separation morphology as in block copolymer materials, but where the scales accessible to this approach of organizing phase-separated fluids usually are significantly larger. Limited experiments confirm the trends observed in our simulations, which should provide some guidance in engineering patterned blend and other mixtures of technological interest.

Morphology, Rheology and Crystallization in Relation to the Viscosity Ratio of Polystyrene/Polypropylene Polymer Blends

Microfibrillar and droplet morphology of polypropylene (PP) phase dispersed in polypropylene (PS) was fabricated by using melt-extrusion. This morphology was obtained by introducing isotactic PP (20 wt.%) with different viscosity in the PS matrix (80 wt.%). Furthermore, the rheological properties of the blend investigated as a function of the viscosity ratio K. The variations in blend morphology were related to crystallization, melting properties, and viscoelasticity. The blends with K >> 1 develop a fine morphology with PP microfibrils along the flow direction, while diameters of the dispersed PP droplets gradually increase with lower values of K = 1, or K << 1. Crystallinity of the prepared blends significantly decreases compared to neat PP, while the microfibrillar morphology induces homogeneous crystallization with small crystallites. This is reflected in a decrease of the crystallization temperature, small loss in the crystallinity, and lower melting temperature of the PS80/PP20 blend compared to neat PP. The storage moduli, loss moduli, and complex viscosity are highest for the microfibrillar morphology that presents retarded relaxation. The rheological properties are dominated by the dispersed phase (K > 1), or matrix (K < 1). The variation in blend properties with microfibrillar morphology can be clearly distinguished from heterogeneous blends containing PP droplets, providing an efficient tool to create a binary blend with unique properties.

A New Solid-like State for Liquid/Liquid/Particle Mixtures with Bicontinuous Morphology of Concentrated Emulsion and Concentrated Suspension

Research in exploring the microstructures of the ternary liquid/liquid/particle mixture is still a challenging task due to the complex interface properties and compositions of each phase. In this work, we report a new kind of solid-like state for ternary mixtures after the addition of a surfactant, which has the bicontinuous morphology of two phases, that is, the concentrated emulsion and the concentrated noncolloidal suspension. The bicontinuous morphology was justified by optical microscopy and the unique two-step yielding behavior under large oscillatory shear flow, which has the yielding character of a noncolloidal suspension at smaller strain and that of a concentrated emulsion at larger strain. A phase diagram is constructed from the rheological measurements and morphological observations. The boundaries of the new solid-like state can be well predicted from three basic requirements on the glass forming or jamming conditions in the aqueous noncolloidal suspension phase, the aqueous emulsion phase, and the whole ternary mixture.

Morphology Mapping of Nanoparticle-Filled Immiscible Polymer Blends in Flow: The Existence of a Critical Ratio between Nanoparticle Concentration and Droplet Concentration

The delicate flow-induced morphology of immiscible polypropylene/polystyrene blends in the presence of silica nanoparticles (NPs) is investigated in a multiparameter space. The morphology map constructed based on in situ morphology observation reveals that a critical ratio of NP concentration to droplet concentration, which strongly depends on the NP surface chemistries and the ratio of the NP concentration to the droplet concentration, exists. Below or above the critical ratio, the NPs display diverse effects on the morphology (promote or suppress droplet coalescence). These results can be interpreted by the competition between the bridging mechanism (acceleratory effect) and the enhanced viscoelasticity (inhibitory effect) exerted by the NPs.

Shear-Induced Migration of Rigid Particles near an Interface between a Newtonian and a Viscoelastic Fluid

Simulations of rigid particles suspended in two-phase shear flow are presented, where one of the suspending fluids is viscoelastic, whereas the other is Newtonian. The Cahn-Hilliard diffuse-interface model is employed for the fluid-fluid interface, which can naturally describe the interactions between the particle and the interface (e.g., particle adsorption). It is shown that particles can migrate across streamlines of the base flow, which is due to the surface tension of the fluid-fluid interface and a difference in normal stresses between the two fluids. The particle is initially located in the viscoelastic fluid, and its migration is investigated in terms of the Weissenberg number Wi (shear rate times relaxation time) and capillary number Ca (viscous stress over capillary stress). Four regimes of particle migration are observed, which can roughly be described by migration away from the interface for Wi = 0, halted migration toward the interface for low Wi and low Ca, particle adsorption at the interface for high Wi and low Ca, and penetration into the Newtonian fluid for high Wi and high Ca. It is found that the angular velocity of the particle plays a large role in determining the final location of the particle, especially for high Wi. From morphology plots, it is deduced that the different dynamics can be described well by considering a balance in the first-normal stress difference and Laplace pressure. However, it is shown that other parameters, such as the equilibrium contact angle and diffusion of the fluid, are also important in determining the final location of the particle.

A microstructure-composition map of a ternary liquid/liquid/particle system with partially-wetting particles

We examine the effect of composition on the morphology of a ternary mixture comprising two molten polymeric liquid phases (polyisobutylene and polyethylene oxide) and micron-scale spherical silica particles. The silica particles were treated with silanes to make them partially wetted by both polymers. Particle loadings up to 30 vol% are examined while varying the fluid phase ratios across a wide range. Numerous effects of particle addition are catalogued, stabilization of Pickering emulsions and of interfacially-jammed co-continuous microstructures, meniscus-bridging of particles, particle-induced coalescence of the dispersed phase, and significant shifts in the phase inversion composition. Many of the effects are asymmetric, for example particle-induced coalescence is more severe and drop sizes are larger when polyisobutylene is the continuous phase, and particles promote phase continuity of the polyethylene oxide. These asymmetries are likely attributable to a slight preferential wettability of the particles towards the polyethylene oxide. A state map is constructed which classifies the various microstructures within a triangular composition diagram. Comparisons are made between this diagram vs. a previous one constructed for the case when particles are fully-wetted by polyethylene oxide.