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High-strength, high-modulus products with a characteristic phase morphology were prepared via the injection molding of blends of isotactic polypropylene (PP) and polyamide-12 (PA-12) under special processing conditions (low melt temperature, high holding pressure, and a convergent sprue design). These conditions generated a situation in which the dispersed phase can be distributed in the self-reinforced matrix as oriented fibrils. Optical (polarized light optical and phase contrast) microscopic and SEM investigations revealed a uniform distribution of the dispersed phase within the matrix. These products can be regarded as in situ thermoplastic composites. The strength level of the self-reinforced blends is approximately twice as high as that of the products processed under conventional conditions. The PA-12 phase dispersed as ultrathin fibrils enhances the flexural impact strength of the blends, decreases their notch sensitivity, and alters its fracture mechanism.

Polymer Blends with Fibrillar Phase Morphology Prepared by Self-Reinforcing Technique: I. Blends of Isotactic Polypropylene and Polyamide-12