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Morphology development was investigated during blending of linear low density polyethylene (LLDPE) and polystyrene (PS) (the minor phase) in a tangential counter-rotating twin screw extruder, with and without the use of 5 wt.-% Kraton styrene-ethylene/butylene-styrene (SEBS) triblock copolymers as compatibilizing agents. Dispersive mixing in the Non-Intermeshing Twin Screw Extruder (NITSE) is improved with an increase of percent drag flow up to 50 %; the screws configuration includes reverse flight elements and/or cylinders. Experiments have indicated that the combined effect of the reverse flight elements and cylinders increases the reduction rate of droplets due to a longer time in the feed screw where the most significant changes of phase morphology occur. Screw stagger has been shown to have a minor effect on the phase scale of the final dispersion. The more significant reduction of the phase scale is achieved by increasing screw speed under constant flow conditions.

Blend Morphology of Linear Low Density Polyethylene and Polystyrene in a Non-Intermeshing Twin Screw Extruder