Surface‐directed morphology evolution in ternary blends of polyethylene, polypropylene, and ethylene–propylene copolymer: A study by laser scanning confocal fluorescence microscopy

Abstract

AbstractWith laser scanning confocal fluorescence microscopy, we demonstrate a novel type of morphology evolution in moderately thick films (70–100 μm) of ternary blends of polypropylene (PP), polyethylene (PE), and ethylene–propylene rubber (EPR), in which EPR is labeled with a benzothioxanthene dye (HY‐EPR). The blends are prepared by solution blending, and the phase morphology evolves during the annealing of the blend films in a stainless steel mold. Our results indicate that wetting of the mold surface is a driving force in morphology evolution for the two blend compositions investigated. For 81/14/5 PP/PE/HY‐EPR, phase evolution within the mold results in a laminar structure and hydrodynamic channels, features which have previously been found in thin films of polymer blends as a result of surface‐directed spinodal decomposition. In a blend with a lower weight fraction of the dispersed phase (92/7/1 PP/PE/HY‐EPR), we find that the PE/HY‐EPR domains are larger and more polydisperse closer to the surface because of wetting of the mold wall. We also show that the phase morphology in these films can be controlled by the nature of one or both of the surfaces being varied. When one of the mold surfaces is replaced with a thin film of PP homopolymer, we observe draining of PE/HY‐EPR from the PP to the mold surface, which results in a bilayer structure. A trilayer morphology is likewise obtained by the replacement of both mold surfaces with PP. We also carry out three‐dimensional image reconstruction on a single PE/HY‐EPR particle within the 81/14/5 PP/PE/HY‐EPR blend to obtain detailed information on the interphase structure. We find that HY‐EPR of this composition (30/70 ethylene/propylene) fully coats the PE dispersed phase and partially penetrates the PE droplets. This result falls between the interphase structures found for previously investigated EPR compositions (40/60 and 80/20 ethylene/propylene). © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 637–654, 2003