Effects of vibration blending on the subsequent crystallization behavior of polycarbonate/polypropylene blends

The effects of blending in a novel vibration internal mixer on the subsequent multiple crystallization of 70/30 w/w polycarbonate (PC)/polypropylene (PP) were investigated by differential scanning calorimetry, wide‐angle X‐ray diffractogram, and microscopy. The vibration internal mixer was reformed from a conventional internal mixer through parallel superposition of an oscillatory shear on a steady shear. For this polypropylene‐minor phase blend, three possible crystallization peaks were observed. The crystallization behavior was sensitive to the sizes and the size distribution of the dispersed polypropylene droplets. Larger amplitude and/or higher‐frequency vibration produced more small droplets (<2 μm) and increased the number of medium droplets (2–8 μm) as a result of the spatially wider and temporally quicker variation of shear rate. The resulting subsequent low‐temperature crystallization peak became larger and shifted to lower temperature, and the intermediate‐temperature peak became obvious. On the contrary, the coalescence of small droplets, resulting from the heating treatment, weakened the low‐temperature peak but strengthened the intermediate‐temperature peak and rendered the high‐temperature peak to be wider. Mixing at the too high amplitude produced the unstable, partially cocontinuous phase morphology restricting the medium droplets and enlarging the surface area, such that the intermediate‐temperature crystallization peak did not appear. Multiple crystallization was related to phase morphology and the nucleation density as well as surface effects. Double‐fusion endotherms of the PP component were also observed, corresponding to the melting of different forms of polypropylene crystals. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 85: 92–103, 2002