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Particles have been demonstrated to toughen epoxy resins, especially for fiber-reinforced epoxy composites, and core/shell particles are one of them. It is known that not all particles toughen the same but most evaluations are through experimentation, and few studies have been conducted to accurately predict the particles’ toughening effect or guide the design of effective particles. In this study, efforts were made to find the control factors of core/shell particles, primarily interfacial compatibility and degree of dispersion, and how to predict them. Nanocomposites were fabricated by incorporating core/shell nanoparticles having various shell polymer compositions, especially their polarities. Their compatibility was estimated using a novel quantitative approach  via  adopting the theory of Hansen solubility parameters (HSP), in which the HSP of core/shell nanoparticles and the epoxy matrix were experimentally determined and compared. It was found that the HSP distance was a good predictor for particle dispersion and interfacial interaction. Particles having a small HSP distance ( Ra ) to the epoxy resin, represented by the polybutylacrylate core/polymethyl methacrylate shell particle having the smallest  Ra  of 0.50, indicated a uniform dispersion and strong interfacial bonding with the matrix and yielded outstanding toughening performance. In contrast, polybutylacrylate core/polyacrylonitrile shell particle having the largest HSP distance (6.56) formed aggregates and exhibited low interfacial interaction, leading to poor toughness. It was also demonstrated that HSP can provide an effective strategy to facilitate the design of effective core/shell nanoparticles for epoxy toughening.

Building effective core/shell polymer nanoparticles for epoxy composite toughening based on Hansen solubility parameters