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Suryasarathi Bose, Arup R. Bhattacharyya, Rupesh A. Khare, Srikanth S. Kamath, Ajit R. Kulkarni
Department of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay,
Powai, Mumbai-400076, India
Multicomponent polymer blends involving polyamide6 structures during processing ranging from matrix-droplet
(PA6), polypropylene (PP), acrylonitrile-butadiene-sty- type and brillar to co-continuous morphologies. The ow
rene (ABS) and high density polyethylene (HDPE) with induced microstructure often determines the end-use prop-
multiwall carbon nanotubes (MWNT) were prepared by
melt mixing technique to achieve conducting compo- erties of the blends. In this context, blends with co-contin-
sites. MWNT were either compounded directly or by uous morphology have emerged with unique properties
employing a masterbatch dilution approach in binary and generated profound interest. Employing a suitable
(PA6/ABS), ternary (PA6/PP/ABS) and quaternary (PA6/ compatibilizer has been described as one of the classical
PP/ABS/HDPE) blends. To facilitate network-like strategies to reduce the interfacial tension between
structure MWNT were pretreated with either sodium
salt of 6-aminohexanoic acid or octadecyl tri-phenyl the components and stabilize the morphology during
phosponium bromide. Multicomponent blends with melt-mixing.
pretreated MWNT utilizing masterbatch dilution In recent years, the concept of using llers to stabilize
approach showed signicant improvements in the bulk the blend morphology has been introduced and received a
electrical conductivity as compared to blends prepared
great deal of interest both from scientic and industrial
by direct addition approach at 2 wt % MWNT content.
Phase morphology of these blends revealed co-contin- perspectives. In this regard, selective lling of conducting
uous type of morphology wherein MWNT were found to llers in one of the phases or at the interface of co-con-
be selectively localized in the PA6 phase. The hetero- tinuous binary immiscible blends has generated profound
nucleating action of MWNT was manifested in interest in designing conducting polymer composites for
increased crystallization temperature of mainly PA6
phase of the blends indicating preferential localization several practical applications [2]. It has been known over
of MWNT in the PA6 phase. POLYM. ENG. SCI., 51:1987 years that selective localization of conducting llers in
2000, 2011. 2011 Society of Plastics Engineers any one of the phases or at the interface of co-continuous
binary immiscible blends is an efcient strategy to
INTRODUCTION develop conducting composites using very low level of
conducting llers utilizing the concept of double perco-
Blending of polymers is often used to design a material lation [3]. In addition, it has been reported that selective
with synergistic combination of desirable properties from localization of ller in co-continuous blends often broad-
each component [1]. The ultimate properties of the blends ens the phase inversion regime [4] and further manifests
are strongly inuenced by the constituent blend compo- in ner ligament size of the phases [5]. The phase
nents, the interface and the morphology developed during morphology of the blends typically depends on the con-
processing. Consequently, most of the polymer mixtures centration, shape, type, and dimension of the ller.
are immiscible which often leads to wide range of micro- Conducting polymer composites involving conducting
llers exhibit an abrupt increase in the bulk electrical con-
Correspondence to: Arup R. Bhattacharyya; e-mail: arupranjan@iitb.ac.in ductivity at a critical concentration of ller termed as
Suryasarathi Bose is currently at Department of Chemical Engineering, percolation threshold. Recently, carbon nanotubes
Katholieke Universiteit Leuven, Willem de Croylaan 46, B-3001 Leuven, (CNT) have received a great deal of interest as conduct-
Belgium. ing ller in polymer composites because of the possibility
Contract grant sponsor: Department of Science and Technology (DST),
to achieve reasonably high conductivity at low CNT
India; contract grant number: 08DST016.
DOI 10.1002/pen.21998
content owing to its high aspect ratio (L/D). In this
Published online in Wiley Online Library (wileyonlinelibrary.com). context, vast efforts have been attempted in restricting
V
C 2011 Society of Plastics Engineers CNT in one of the phases or at the interface of binary
Sample Codes
Polyamide 6 PA6
Polypropylene PP
High density polyethylene HDPE
50/50 blends of PA6 and ABS Sample 1
40/30/30 PA6/PP/ABS blends Sample 2
34/33/33 PA6/PP/ABS blends Sample 3
30/25/25/20 PA6/PP/ABS/HDPE blends Sample 4
50/50 PA6/ABS blends with 2 wt% p-MWNT (without any pretreatment, direct addition) Sample 5
40/30/30 PA6/PP/ABS Blends with 2 wt% p-MWNT (without any pretreatment, direct addition) Sample 6
30/25/25/20 PA6/PP/ABS/HDPE Blends with 2 wt% p-MWNT (without any pretreatment, direct addition) Sample 7
50/50 PA6/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, direct addition) Sample 8
40/30/30 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, direct addition) Sample 9
34/33/33 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, direct addition) Sample 10
30/25/25/20 PA6/PP/ABS/HDPE blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, direct addition) Sample 11
50/50 PA6/ABS blends with 2 wt% p-MWNT (without any pretreatment, masterbatch) Sample 12
40/30/30 PA6/PP/ABS Blends with 2 wt% p-MWNT (without any pretreatment, masterbatch) Sample 13
34/33/33 PA6/PP/ABS Blends with 2 wt% p-MWNT (without any pretreatment, masterbatch) Sample 14
30/25/25/20 PA6/PP/ABS/HDPE Blends with 2 wt% p-MWNT (without any pretreatment, masterbatch) Sample 15
50/50 PA6/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, masterbatch) Sample 16
40/30/30 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, masterbatch) Sample 17
34/33/33 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, masterbatch) Sample 18
30/25/25/20 PA6/PP/ABS/HDPE blends with 2 wt% MWNT (pretreated with Na-AHA in 1:1 wt ratio, masterbatch) Sample 19
50/50 PA6/ABS blends with 2 wt% MWNT (pretreated with OTPB in 1:1 wt ratio, masterbatch) Sample 20
40/30/30 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with OTPB in 1:1 wt ratio, masterbatch) Sample 21
34/33/33 PA6/PP/ABS blends with 2 wt% MWNT (pretreated with OTPB in 1:1 wt ratio, masterbatch) Sample 22
30/25/25/20 PA6/PP/ABS/HDPE blends with 2 wt% MWNT (pretreated with OTPB in 1:1 wt ratio, masterbatch) Sample 23
Binary (PA6/ABS, 50/50 wt/wt), ternary (PA6/PP/ were: injection pressure 3 bar, melt temperature 2608C,
ABS, 40/30/30, and 34/33/33 wt/wt/wt) and quaternary mold temperature 608C, holding time 60 s and cooling
blends (PA6/PP/ABS/HDPE, 30/25/25/20 wt/wt/wt/wt) time 23 min.
with MWNT were prepared by melt-mixing in a conical
twin-screw microcompounder (Micro 5, DSM Research,
Netherlands). Two different protocols of melt-mixing viz.
Characterization
direct compounding (simultaneous mixing) and master-
batch dilution approach were followed to prepare the mul- Electrical Conductivity. The alternating current (AC)
ticomponent blends with MWNT. For direct addition pro- electrical conductivity measurements were performed on
tocol, MWNT were compounded simultaneously with the the injection molded samples (across the thickness) in the
constituent polymers at 2608C with a rotational speed of frequency range between 1021 and 106 Hz using Alpha
150 rpm for 15 min. In the masterbatch dilution protocol, high resolution analyzer coupled to a Novocontrol inter-
masterbatches of PA6 and MWNT (without or with pre- face.
treated Na-AHA and OTPB) were prepared (under the
same extrusion conditions mentioned above except for the SEM and Solution Experiments. The phase morphol-
mixing time which was xed at 10 min) prior to com- ogy of the multicomponent polymer blends were investi-
pounding with the other constituents. Required amount of gated by SEM. Extrudate samples were cryofractured in
the masterbatch was then subsequently diluted further in liquid nitrogen and either etched with tetrahydrofuran
the next step of melt-mixing under the same extrusion (THF) to selectively etch the ABS phase or in hot xylene
condition mentioned above except for the mixing time of to selectively etch both PP and HDPE phases from the
10 min. All blend components were predried in vacuum blends. The etched surface was gold sputtered to avoid
oven at 808C for 24 h. All the experiments were per- charging of the sample. These samples were then
formed under nitrogen atmosphere in order to prevent oxi- observed under SEM using Hitachi S3400N. For solution
dative degradation of the components. The blend compo- experiment, small pieces of extrudate strands (corre-
sitions with their sample codes are listed in Table 1. sponding to 10 mg of MWNT) were dissolved in the
Injection molded samples (according to ASTM D 638, respective solvents to dissolve completely the phases. The
Type V, thickness: 3 mm; gauge length: 12 mm; width: vials were photographed after 24 h.
10 mm) were prepared using mini-injection molding
machine from DSM Research Netherlands. The injection- % Cocontinuity Measurements. The continuity of
molding parameters maintained for all the compositions the PA6 phase (%) in the multicomponent blends was
DHm
Xc 100 (1) FIG. 1. AC electrical conductivity of multicomponent blends with
DHm
o f
MWNT (2 wt%) (a) direct addition; and (b) masterbatch dilution approach.
these blends. To get further insight into the continuity of tion experiment was carried out. Figure 5a depicts the so-
the phases the morphology of the ternary blends was also lution experiment for quaternary blends wherein the
investigated by removing only ABS phase (by THF). Fig- extruded strand has been dissolved in the formic acid.
ure 3e shows the co-continuous PA6 and PP phases pres- The black color of solution observed in all the blends
ent in the blends. Higher magnication image of the (Fig. 5a, vials 14) suggests that MWNT are predomi-
blends shows the presence of MWNT (observed as white nantly localized in the PA6 phase. On the other hand, the
dots) predominantly in the PA6 phase (see Fig. 3f). extruded strand dissolved in the THF (for ABS phase,
Figure 4 shows the SEM micrographs of quaternary Fig. 5b) and xylene (for PP and HDPE phase, Fig. 5c)
blends of 30/25/25/20 PA6/PP/ABS/HDPE. The samples separately do not exhibit any black color, suggesting
here have been etched with hot xylene to remove both PP MWNT are not localized in the ABS phase irrespective
and HDPE phases from the blends and followed by THF of their modication. Similarly, the solution experiment
to remove the ABS phase. PA6 phase is observed to form for binary and ternary blends also conrmed the presence
continuous structure in all the quaternary blends. Blends of MWNT predominantly in the PA6 phase irrespective
with masterbatch of OTPB modied MWNT show signi- of the modication (The gures corresponding to solution
cant renement in the phase dimension of PA6 phase as experiment of binary and ternary blends have not been
compared to the blends with p-MWNT, masterbatch of p- incorporated to avoid the repeatation).
MWNT and masterbatch of Na-AHA modied MWNT. The qualitatively observed cocontinuity of the PA6
Further, the strands have been observed to be intact even phase during SEM is quantied through % cocontinuity
after extraction of ABS, PP and HDPE phases which con- determination as explained in the experimental section.
tribute to 70 wt% of the composite. Higher magnication Table 3 enlists the % cocontinuity of the PA6 phase in all
image (Fig. 4e) of the blends with masterbatch of OTPB the blends. As observed from the Table 3, quaternary
modied MWNT shows MWNT involved in the forma- blends show relatively less cocontinuity for the PA6
tion of network-like structure in the PA6 phase contrib- phase as compared to binary and ternary blends irrespec-
uting towards higher electrical conductivity. tive of the modication of MWNT. The observed lower
To illustrate further the selective localization of % cocontinuity of quaternary blends could be because of
MWNT in the binary, ternary and quaternary blends; solu- the change in the melt viscosity ratio of blends, interfacial
tension between the constituent polymers or blends com- nucleating agents in PP [28], HDPE [29], PA6 [30] result-
position [17]. ing in an increase in degree of crystallinity and crystalli-
zation temperature. The nucleating ability of MWNT
depends strongly on the state of dispersion of MWNT in
Crystallization Behavior of Blends With MWNT
blends. DSC analysis of binary, ternary and quaternary
Presence of MWNT inuences greatly the crystalliza- blends has been carried out to investigate the crystalliza-
tion behavior of polymers. MWNT are found to act as tion behavior of PA6, PP, and HDPE in the blends, in
presence of MWNT which could unequivocally conrm earlier been reported in the literature [3133]. Interest-
the presence of MWNT in a specic phase. ingly, blends with OTPB modied MWNT show a single
Figure 6a shows the crystallization exotherms for bi- crystallization exotherm at 1948C i.e. at a temperature
nary 50/50 PA6/ABS blends with MWNT. Neat blends lower than the rst crystallization peak temperature of
show a single crystallization peak (Tc) centered at PA6 in blends with MWNT or Na-AHA modied MWNT
1928C corresponding to PA6. Addition of MWNT (with (1968C), however Tc of PA6 is higher than bulk Tc of
or without any pretreatment) results in a signicant pure PA6 indicating the heteronucleating action of OTPB
increase in the crystallization temperature. Tc is observed modied MWNT as well.
to be 1968C for blends with MWNT prepared by direct Figure 6b shows the crystallization exotherms for ter-
addition as well as masterbatch dilution approach (see nary PA6/PP/ABS 40/30/30 (wt/wt/wt) blends with
Table 4 for crystallization behavior of PA6 in blends). Tc MWNT. Neat blends show two crystallization exotherms
is slightly lower (1958C) for blends with Na-AHA centered at 1168C and 1918C corresponding to the
modied MWNT as compared to blends with unmodied bulk crystallization temperature of PP and PA6, respec-
MWNT. tively. Addition of MWNT results in the signicant
Interestingly, blends with MWNT and blends with Na- increase in the crystallization temperature of PA6 whereas
AHA modied MWNT show an additional crystallization only marginal increase is observed in crystallization tem-
exotherm centered at 2088C. The appearance of second perature of PP (see Table 5 for crystallization behavior of
crystallization exotherm in PA6/MWNT composites has PP in blends). Similar to the binary blends, addition of
melting behavior of PA6 in blends (discussed in the sub- 2208C. Neat ternary blends in addition to two melting
sequent section). In this study, the presence of second endotherms of PA6, show an additional melting endo-
crystallization exotherm for blends with MWNT and Na- therm around 1608C corresponding to PP phase. Neat
AHA modied MWNT indicates that surface of MWNT quaternary blends show two melting endotherms for PA6
is unaffected upon the modication with Na-AHA. around 2158C and 2208C and one melting endotherm each
Improved state of dispersion of MWNT after modication for PP and HDPE at around 1608C and 1318C, respec-
with Na-AHA indicates that debundling of MWNT is tively. All the blends with MWNT (MWNT/Na-AHA
achieved in the initial stages of preparation and subse- modied MWNT or OTPB modied MWNT) show single
quently during the melt mixing melt interfacial reaction melting endotherm for PA6 around 2208C and a slight
may take place between amine functionality of Na-AHA increase in melting temperature of PP and HDPE. Further,
and acid end-group of PA6; Na-AHA thereby detaches blends with modied MWNT (Na-AHA as well as OTPB)
from the surface of MWNT leaving the surface available exhibit slightly lower melting temperature for PA6 as
for the nucleation of PA6 lamella. Whereas in the case of compared to neat blends and blends with MWNT. Lower
blends with OTPB modied MWNT, the surface is likely melting temperature of PA6 conrms the plasticizing
to be partially covered with OTPB making the nucleation action of the modiers on PA6 component.
of PA6 lamella difcult for second crystallization exo- The double melting endotherms may arise from the
therm. Further, OTPB modied MWNT are found to be presence of two crystalline forms of PA6; pseudohexago-
less effective nucleating agent resulting in lower crystalli- nal c-crystalline form and monoclinic a-crystalline form
zation temperature of PA6 in blends as compared to or due to a process melting-recrystallization-melting
blends with MWNT. phenomenon [35]. Lower melting endotherm corresponds
Figure 7ad shows the melting endotherms respectively to metastable c-crystalline form whereas relatively higher
for binary, ternary and quaternary blends with or without temperature melting endotherm corresponds to a-crystal-
pretreated MWNT. Neat binary blends show two melting line form. It has been observed that the presence of
endotherms corresponding to PA6 at around 2158C and both the crystalline forms of PA6 may arise due to the
Composition Tc (8C) Tm (8C) DHm (J/g) Xc (%) Composition Tc (8C) Tm (8C) DHm (J/g) Xc (%)
PA6 192 220 76.8 37.5 HDPE 118 133 220.4 76.0
Sample 1 192 220 80.2 39.2 Sample 4 117 131 166.0 57.3
Sample 3 191 221 40.8 19.9 Direct addition
Sample 2 191 220 49.9 24.1 Sample 7 117 131 147.9 51.0
Sample 4 191 220 51.4 25.1 Sample 11 117 131 149.7 51.7
Direct addition Masterbatch approach
Sample 5 196, 208 220 50.4 24.6 Sample 15 117 132 141.4 48.8
Sample 6 196, 209 220 60.4 29.5 Sample 23 117 132 125.9 43.4
Sample 7 195, 210 221 38.4 18.8
Sample 8 195, 207 220 67.3 32.9 The degree of crystallinity of HDPE phase in multicomponent blends
Sample 9 195, 207 219 56.2 27.5 was calculated as: Xc (DHm normalized/DHom ) 3 100 where DHom
Sample 10 194, 207 219 54.0 26.4 290 J/g.
Sample 11 194, 207 219 45.7 22.3
Masterbatch approach
Sample 12 196, 208 220 49.9 24.4
Sample 13 196, 208 220 65.8 32.1
processing induced crystallization viz. in case of injection
Sample 14 195, 208 220 65.2 31.8 molding. Wide angle X-ray diffraction studies conrmed
Sample 15 195, 209 221 39.2 19.2 the existence of only single crystalline form, a for PA6
Sample 16 195, 208 220 67.1 32.8 in compression molded lms of PA6/MWNT composites
Sample 17 195, 208 219 65.0 31.7 whereas both the polymorphic forms were observed in
Sample 18 194, 208 219 57.9 28.0
Sample 20 194 220 58.8 28.7
injection molded specimens [31]. Further, existence of
Sample 21 194 220 57.9 28.3 single melting endotherm in blends with MWNT elimi-
Sample 22 194 220 49.0 24.0 nates the possibility of second crystallization peak arising
Sample 23 193 220 40.0 19.5 from formation of different crystalline morphology.
The degree of crystallinity of PA6 phase in multicomponent blends
was calculated as: Xc (DHm normalized/DHom ) 3 100 where DHom
204.8 J/g. CONCLUSIONS
In summary, signicant improvements in AC electrical
conductivity of co-continuous binary (PA6/ABS), ternary
(PA6/PP/ABS) and quaternary (PA6/PP/ABS/HDPE)
polymer blends with MWNT pretreated with either Na-
TABLE 5. Crystallization temperature (8C), melting temperature (8C),
heat ow (J/g), and degree of crystallanity (%) of PP in ternary and
AHA or OTPB was achieved by utilizing masterbatch
quaternary blends. dilution approach mediated by specic interaction in con-
junction with melt interfacial reaction during melt-mixing.
Composition Tc (8C) Tm (8C) DHm (J/g) Xc (%) The large organic tail lengths of OTPB had a greater
inuence on the state of dispersion of MWNT and on the
Sample 3 116 160 154 74.6
Sample 2 117 160 138 66.8
subsequent bulk AC electrical conductivity in multicom-
Sample 4 117 160 166 57.3 ponent blends.
Direct addition Masterbatch dilution approach has resulted in selective
Sample 6 117 160 118.1 57.0 localization of pretreated MWNT in the PA6 phase of the
Sample 7 117 160 127.0 61.4
multicomponent blends leading to improvement in AC
Sample 10 118 160 48.1 23.2
Sample 9 118 160 53.5 25.9
electrical conductivity as compared to the blends prepared
Sample 11 117 160 58.3 28.2 by direct addition protocol. SEM and solution experi-
Masterbatch approach ments further supported the selective localization of
Sample 13 115 159 66.6 32.2 MWNT in the PA6 phase. The crystallization behavior of
Sample 14 115 159 81.6 39.4 the blend constituents, mainly PA6 phase was greatly
Sample 15 117 160 130.7 63.2
Sample 17 117 160 68.2 33.0 affected by the presence of MWNT in the blends as indi-
Sample 18 118 160 68.6 33.1 cated from the varying Tc corresponding to the PA6
Sample 21 115 160 71.4 34.5 phase; further substantiating the localization of major
Sample 22 114 159 65.2 31.5 fraction of MWNT in the PA6 phase.
Sample 23 117 160 53.0 25.6 Overall, it can be concluded that masterbatch dilution
The degree of crystallinity of PP phase in multi-component blends
process has been found to be effective in restricting
was calculated as: Xc (DHm normalized/DHom ) 3 100 where DHom MWNT specically in one of the phases in multicompo-
207.1J/g. nent blends provided MWNT could be modied by
Na-AHA or OTPB. This has resulted in renement of 7. R. Khare, A.R. Bhattacharyya, A.R. Kulkarni, M. Sar-
network-like structure of MWNT in a continuous PA6 oop, and A. Biswas, J. Polym. Sci. B: Phys, 46, 2286
phase. (2008).
8. R. Tchoudakov, O. Breuer, M. Narkis, and A. Siegmann,
Polym. Engg. Sci., 36, 1336 (1996).
ACKNOWLEDGMENTS
9. F. Gubbels, R. Jerome, E. Vanlathem, R. Deltour, S.
The authors would also like to thank Micro- Blacher, and F. Brouers, Chem. Mater., 10, 1227 (1998).
compounder Central facility at IIT Bombay. 10. P. Potschke, A.R. Bhattacharyya, and A. Janke, Polymer,
44, 8061 (2003).
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