Effect of the dispersed phase fraction on particle size in blends with high viscosity ratio

It has been reported that for polymer blends with high viscosity ratio (>1), the size of the dispersed particles decreases with increasing volume fraction of the dispersed phase. In order to explain this effect, an equation was derived for the affine deformation of an imaginary plane of the dispersed phase in stratified two-phase steady, simple, shear flow. The model predicts that for viscosity ratio >1, the deformation rate increases with volume fraction of the dispersed phase, and the shear stress also increases, leading to an increase of the breakup time. Therefore, the total deformation of the dispersed phase, before breakup, increases with increase of volume fraction, resulting in a decrease of the size of the dispersed phase particles. Accordingly, one can expect that in industrial mixers, the particle size of the blends should decrease as the volume fraction increases, if coalescence is suppressed. Experiments were carried out in a Haake batch mixer, using polyethylene/polyamide-6 blends compatibilized by adding maleic anhydride grafted polyethylene. Particle size decreased up to 20 wt% polyamide-6, at 100, 150, and 200 RPM, and increased between 20 and 30 wt%. The decrease of the particle size is mainly due to increased deformation of the dispersed phase. The increase of the particle size above 20 wt% is due to coalescence at high fractions.