Effects of extensional flow on properties of polyamide‐66/poly(2,6‐dimethyl‐1,4‐phenylene oxide) blends: A study of morphology,mechanical properties,and rheology

In this study, polyamide‐66/poly(2,6‐dimethyl‐1,4‐phenylene oxide) (PA66/PPO) blends with high viscosity ratio were processed by a self‐designed triangle‐arrayed triple‐screw extruder (TTSE, which simulates extensional flow) and a commercial twin‐screw extruder (TSE), respectively. Furthermore, in order to improve the mechanical properties of the immiscible PA66/PPO blends, PPO‐grafted maleic anhydride (PPO‐g‐MA) and styrene–ethylene–butylene–styrene (SEBS) block copolymer were used. The mechanical properties, phase morphology, and rheological properties of both binary PA66/PPO blends and toughened PA66/PPO/PPO‐g‐MA blends were comprehensively investigated to compare the above mentioned two processing method. Samples processed with TTSE exhibited better mechanical properties than the TSE‐processed blends. The morphologies of the blends were examined by scanning electron microscopy, exhibiting smaller particles sizes and narrower particle size distributions, which were attributed to the significant effects of extensional flow in TTSE. The toughening mechanism of compatibilized blends was investigated through morphology analysis, dynamic mechanical, and rhelogical analysis. Thus, TTSE with an extensional effect was proved to be efficient in the blending of high viscosity ratio polymers. POLYM. ENG. SCI., 57:1090–1098, 2017. © 2016 Society of Plastics Engineers     

Blends of poly(2,6‐dimethyl‐1,4‐phenylene oxide)/polyamide 6 toughened by maleated polystyrene‐based copolymers: Mechanical properties,morphology, and rheology

Poly(2,6‐dimethyl‐1,4‐phenylene oxide)/polyamide 6 (PPO/PA6 30/70) blends were impact modified by addition of three kinds of maleated polystyrene‐based copolymers, i.e., maleated styrene‐ethylene‐butylene‐styrene copolymer (SEBS‐g‐MA), maleated methyl methacrylate‐butadiene‐styrene copolymer (MBS‐g‐MA), and maleated acrylonitrile‐butadiene‐styrene copolymer (ABS‐g‐MA). The mechanical properties, morphology and rheological behavior of the impact modified PPO/PA6 blends were investigated. The selective location of the maleated copolymers in one phase or at interface accounted for the different toughening effects of the maleated copolymer, which is closely related to their molecular structure and composition. SEBS‐g‐MA was uniformly dispersed in PPO phase and greatly toughened PPO/PA6 blends even at low temperature. MBS‐g‐MA particles were mainly dispersed in the PA6 phase and around the PPO phase, resulting in a significant enhancement of the notched Izod impact strength of PPO/PA6 blends from 45 J/m to 281 J/m at the MBS‐g‐MA content of 20 phr. In comparison, the ABS‐g‐MA was mainly dispersed in PA6 phase without much influencing the original mechanical properties of the PPO/PA6 blend. The different molecule structure and selective location of the maleated copolymers in the blends were reflected by the change of rheological behavior as well. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Study on the microstructures and mechanical behaviour of compatibilized polypropylene/polyamide‐6 blends

A series of blends of polypropylene (PP)–polyamide‐6 (PA6) with either reactive polyethylene–octene elastomer (POE) grafted with maleic anhydride (POE‐g‐MA) or with maleated PP (PP‐g‐MA) as compatibilizers were prepared. The microstructures and mechanical properties of the blends were investigated by means of tensile and impact testing and by scanning electron microscopy and transmission electron microscopy. The results indicated that the miscibility of PP–PA6 blends was improved with the addition of POE‐g‐MA and PP‐g‐MA. For the PP/PA6/POE‐g‐MA system, an elastic interfacial POE layer was formed around PA6 particles and the dispersed POE phases were also observed in the PP matrix. Its Izod impact strength was four times that of pure PP matrix, whilst the tensile strength and Young's modulus were almost unchanged. The greatest tensile strength was obtained for PP/PA6/PP‐g‐MA blend, but its Izod impact strength was reduced in comparison with the pure PP matrix. © 2002 Society of Chemical Industry     

Relationship between structure and properties in high‐performance PA6/SEBS‐g‐MA/(PPO/PS) blends: The role of PPO and PS

This work aimed at studying the role of poly(phenylene oxide) (PPO) and polystyrene (PS) in toughening polyamide‐6 (PA6)/styrene‐ethylene‐butadiene‐styrene block copolymer grafted with maleic anhydride (SEBS‐g‐MA) blends. The effects of weight ratio and content of PPO/PS on the morphology and mechanical behaviors of PA6/SEBS‐g‐MA/(PPO/PS) blends were studied by scanning electron microscope and mechanical tests. Driving by the interfacial tension and the spreading coefficient, the “core–shell” particles formed by PPO/PS (core) and SEBS‐g‐MA (shell) played the key role in toughening the PA6 blends. As PS improved the distribution of the “core–shell” particles due to its low viscosity, and PPO guaranteed the entanglement density of the PPO/PS phase, the 3/1 weight ratio of PPO/PS supplied the blends optimal mechanical properties. Within certain range, the increased content of PPO/PS could supply more efficient toughening particles and bring better mechanical properties. Thus, by adjusting the weight ratio and content of PPO and PS, the PA6/SEBS‐g‐MA/(PPO/PS) blends with excellent impact strength, high tensile strength, and good heat deflection temperature were obtained. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45281.     

Blends of SBS triblock copolymer with poly(2,6‐dimethyl‐1,4‐phenylene oxide)/polystyrene mixture

Blends of styrene–butadiene–styrene (SBS) or styrene–ethylene/1‐butene–styrene (SEBS) triblock copolymers with a commercial mixture of polystyrene (PS) and poly(2,6‐dimethyl‐1,4‐phenylene oxide) (PPO) were prepared in the melt at different temperatures according to the chemical kind of the copolymer. Although solution‐cast SBS/PPO and SBS/PS blends were already known in the literature, a general and systematic study of the miscibility of the PS/PPO blend with a styrene‐based triblock copolymer in the melt was still missing. The thermal and mechanical behavior of SBS/(PPO/PS) blends was investigated by means of DSC and dynamic thermomechanical analysis (DMTA). The results were then compared to analogous SEBS/(PPO/PS) blends, for which the presence of a saturated olefinic block allowed processing at higher temperatures (220°C instead of 180°C). All the blends were further characterized by SEM and TGA to tentatively relate the observed properties with the blends' morphology and degradation temperature. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2698–2705, 2003     

Miscibility and specific interactions in blends of poly(vinyl phenyl ketone hydrogenated) with poly(2,6‐dimethyl‐1,4‐phenylene oxide)

The miscibility behavior of poly(vinyl phenyl ketone hydrogenated) (PVPhKH) and poly(2,6‐dimethyl‐1,4‐phenylene oxide) (PPO) are studied by differential scanning calorimetry, thermomechanical analysis, and FTIR spectroscopy. Two miscibility windows between 10 to 40 and 60 to 90 wt % PPO are detected. Only the blend with 50 wt % PPO is immiscible. The best fit of the Gordon–Taylor equation of the experimental glass‐transition temperatures for miscible PVPhKH/PPO blends is shown. A study by FTIR spectroscopy suggests that hydrogen bonding interactions are formed between the hydroxyl groups of PVPhKH and the ether groups of PPO. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1887–1892, 2004     

Solvothermal process for grafting dibutylmaleate onto poly(ethylene‐co‐1‐octene)

Solvothermal process was successfully developed to graft dibutylmaleate (DBM) onto poly(ethylene‐co‐1‐octene) (POE) with dicumyl peroxide (DCP) as free radical‐initiator. FTIR spectra demonstrate that DBM is successfully grafted onto the backbone of POE by this novel method. The influences of DBM content, DCP concentration, POE concentration, reaction temperature and reaction time on the grafting copolymerization have been investigated in detail through grafting degree (GD). It is worthy to indicate that high grafting degree (above 15%) can be achieved through the one‐pot way when the graft reaction is carried out in 40 mL toluene at 150°C for 5 h with 1.6 g DBM, 6–8 g POE and 0.35 g DCP. This developed solvothermal process is becoming an effective way to prepare POE‐g‐DBM graft copolymers, and can be extended to other systems. In addition, TGA results show that the thermal properties of POE are enhanced after the grafting reaction. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Effect of ethylene–acrylate–(maleic anhydride) terpolymer on mechanical properties and morphology of poly(ethylene terephthalate)/polyamide‐6 blends

Background: Poly(ethylene terephthalate) (PET)/polyamide‐6 (PA‐6) blends are promising for engineering and food‐packaging applications. However, their poor toughness limits their use. In this study, an ethylene–acrylate–(maleic anhydride) terpolymer (E‐AE‐MA) was added to PET/PA‐6 blends in order to improve the toughness. Results: Izod impact tests indicated an excellent toughening effect of E‐AE‐MA. E‐AE‐MA particles were observed to be selectively dispersed at the interface between PET and PA‐6 phases and in the domain of the PA‐6 phase. Fourier transform infrared spectroscopy and differential scanning calorimetry results demonstrated that the formation of E‐AE‐MA layers around PA‐6 particles cut off the interaction between PET and PA‐6, resulting in an enlarged PA‐6 phase domain. Conclusion: Based on the experimental results, a core–shell microstructure, with PA‐6 as a hard core and E‐AE‐MA as a soft shell, could be suggested. The formation of this core–shell microstructure, along with the increased PA‐6 phase domain size, is the main toughening mechanism of E‐AE‐MA in PET/PA‐6 blends. Copyright © 2007 Society of Chemical Industry     

Improvement of compatibility of poly(ethylene terephthalate) and poly(ethylene octene) blends by γ‐irradiation

Blends of poly(ethylene terephthalate) (PET) and poly(ethylene octene) (POE) were prepared by melt blending with various amounts of trimethylolpropane triacylate (TMPTA). The mechanical properties, phase morphologies, and gel fractions at various absorbed doses of γ‐irradiation have been investigated. It was found that the toughness of blends was enhanced effectively after irradiation as well as the tensile properties. The elongation at break for all studied PET/POE blends (POE being up to 15 wt %) with 2 wt % TMPTA reached 250–400% at most absorbed doses of γ‐irradiation, approximately 50–80 times of those of untreated PET/POE blends. The impact strength of PET/POE (85/15 wt/wt) blends with 2 wt % TMPTA irradiated with as little as 30 kGy absorbed dose exceeded 17 kJ/m², being approximately 3.4 times of those of untreated blends. The improvement of the mechanical properties was supported by the morphology changes. Scanning electron microscope images of fracture surfaces showed a smaller dispersed phase and more indistinct inter‐phase boundaries in the irradiated blends. This indicates increased compatibility of PET and POE in the PET/POE blends. The changes of the morphologies and the enhancement of the mechanical properties were ascribed to the enhanced inter‐phase boundaries by the formation of complex graft structures confirmed by the results of the gelation extraction and Fourier Transform Infrared analyses. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Phase behavior of binary and ternary blends of poly(styrene‐co‐methacrylic acid), poly(styrene‐co‐4‐vinylpyridine), and poly(2,6‐dimethyl‐1,4‐phenylene oxide)

Poly(styrene‐co‐methacrylic acid) (PSMA) and poly(styrene‐co‐4‐vinylpyridine) (PS4VP) of different compositions were prepared and characterized. The phase behavior of these copolymers as binary PSMA/PS4VP mixtures or with poly(2,6‐dimethyl‐1,4‐phenylene oxide) (PPO) as PPO/PSMA or PPO/PS4VP and PPO/PSMA/PS4VP ternary blends was investigated by differential scanning calorimetry (DSC). This study showed that PPO was miscible with PS4VP containing up to 15 mol % 4‐vinylpyridine (4VP) but immiscible with PS4VP‐30 (where the number following the hyphen refers to the percentage 4VP in the polymer) and PSMA‐20 (where the number following the hyphen refers to the percentage methacrylic acid in the polymer) over the entire composition range. To examine the morphology of the immiscible blends, scanning electron microscopy was used. Because of the hydrogen‐bonding specific interactions that occurred between the carboxylic groups of PSMA and the pyridine groups of PS4VP, chloroform solutions of PSMA‐20 and PS4VP‐15 formed interpolymer complexes. The obtained glass‐transition temperatures (T_g's) of the PSMA‐20/PS4VP‐15 complexes were found to be higher than those calculated from the additivity rule. Although, depending on the content of 4VP, the shape of the T_g of the PPO/PS4VP blends changed from concave to S‐shaped in the case of the miscible blends, two T_g were observed with each PPO/PS4VP‐30 and PPO/PS4VP‐40 blend. The thermal stability of the PSMA‐20/PS4VP‐15 interpolymer complexes was studied by thermogravimetry. On the basis of the obtained results, the phase behavior of the ternary PPO/PSMA‐20/PS4VP‐15 blends was investigated by DSC. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Effect of nylon 6 on fracture behavior and morphology of tough blends of poly(2, 6‐dimethyl‐1,4‐phenylene oxide) and maleated styrene‐ethylene‐butadiene‐styrene block copolymer

Ternary blends of poly(2,6‐dimethyl‐1,4‐phenylene oxide) (PPO), nylon 6, and styrene‐ethylene‐butadiene‐styrene block copolymer grafted with maleic anhydride (SEBS‐g‐MA) were prepared via a melt extrusion, and the fracture behavior, morphology, mechanical properties, and rheology were studied. The compatibilization of the blended components was confirmed by differential scanning calorimetry (DSC) analysis. Mechanical properties evaluation demonstrated that incorporation of nylon 6 resulted in an improvement of the tensile strength, but reduction of both the notched Izod impact strength and elongation at break. Transmission electron microscopy (TEM) observation revealed that the network structure of SEBS‐g‐MA domain was gradually destroyed by incorporating the nylon 6. A conversion of SEBS‐g‐MA domain from the network to the irregular dispersed phase took place when the nylon 6 content reached 20 wt %, which resulted in a reduction of the impact strength. Fracture morphology implied that increase of the tensile strength was caused by the plastic deformation of matrix. Rheology investigation indicated that the melt viscosities could be reduced significantly with increasing the content of nylon 6; thus, the processability was improved. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 99:3336–3343, 2006     

Toughening effects of poly(butylene terephthalate) with blocked isocyanate‐functionalized poly(ethylene octene)

BACKGROUND: Blocked isocyanate‐functionalized polyolefins have great potential for use in semicrystalline polymer blends to obtain toughened polymers. In this study, poly(butylene terephthalate) (PBT) was blended with allyl N‐[2‐methyl‐4‐(2‐oxohexahydroazepine‐1‐carboxamido)phenyl] carbamate‐functionalized poly(ethylene octene) (POE‐g‐AMPC). RESULTS: New peaks at 2272 and 1720 cm^?1, corresponding to the stretching vibrations of NCO and the carbonyl of NH? CO? N, respectively, in AMPC, appeared in the infrared spectrum of POE‐g‐AMPC. Both rheological and X‐ray photoelectron spectroscopy results indicated a new copolymer was formed in the reactive blends. Compared to uncompatibilized PBT/POE blends, smaller dispersed particle sizes with narrower distribution were found in the compatibilized PBT/POE‐g‐AMPC blends. There was a marked increase in impact strength by about 10‐fold over that of PBT/POE blends with the same rubber content and almost 30‐fold higher than that of pure PBT when the POE‐g‐AMPC content was 25 wt%. CONCLUSION: The blocked isocyanate‐functionalized POE is an effective toughener for semicrystalline polymers. Super‐toughened PBT blends can be obtained when the POE‐g‐AMPC content is equal to or more than 15 wt%. Copyright © 2009 Society of Chemical Industry     

Preparation of a new filament based on polyamide‐6 for three‐dimensional printing

Fused deposition modeling (FDM) is one of the trendiest three‐dimensional printing (3DP) technologies. However, FDM products based on virgin polyamide‐6 (PA6) are seriously warped due to the accumulation of shrinkage stress generated from the crystallization of PA6. To solve this problem, maleic anhydride grafted poly(ethylene 1‐octene) (POE‐g‐MAH) is added into PA6 to disturb the crystallization and reduce the shrinkage stress. Besides, rigid polystyrene (PS) with good flowability is further introduced to PA6/POE‐g‐MAH blend because too much addition of POE‐g‐MAH will weaken the PA6/POE‐g‐MAH, which will interrupt the printing process. The POE‐g‐MAH and PS both act as amorphous phase in the blends, which will reduce the shrinkage stress and is helpful to the shape stability of the printed products. Finally, a new kind of PA6‐based filament with good toughness for FDM is prepared via this facile method. POLYM. ENG. SCI., 57:1322–1328, 2017. © 2017 Society of Plastics Engineers     

Kinetic studies of the reactive compatibilization of polyamide 6, polycarbonate and poly(propylene oxide)

The kinetics of the reactive blending process occurring during the stirred melting of polyamide 6/polycarbonate (PA6/PC), polyamide 6/polycarbonate/poly(propylene oxide) (PA6/PC/PPO) in a Haake internal mixer at 240°C were investigated. In the PA6/PC blends the formation of copolymers can be observed and they act as compatibilizing agents, raising the miscibility of these blends. In the PA6/PC/PPO blends, the composition is very important in creating the PA6-PC copolymers. The rise of the PPO percentage increases the mobility of the PA6 molecules and the probability of formation of PA6-PC copolymers in PA6/PC/PPO blends with 10% w/w of PC. The PPO percentage (3-10 phr) influences the kinetics of reaction of PA6/PC/PPO ternary blends with a constant PA6/PC mass ratio (85/15).     

Blends of polyamide 6, polycarbonate,and poly(propylene oxide). II. Reactive compatibilization–thermal degradation relationships

The thermal degradation of some blends of polyamide 6/polycarbonate (PA6/PC) and polyamide 6/polycarbonate/poly(propylene oxide) (PA6/PC/PPO) were investigated. The copolymer formed during the mixing of polyamide 6 and polycarbonate, at 240°C, for 30 min, increases the thermal stability of PA6/PC and of PA6/PC/PPO blends. This increase in the thermal stability occurs due to the plasticizing effect of PPO, which increases the mobility of the molecules of PA6 and PC, and consequently increases the probability of the reaction between the —NH₂ and —O—CO—O groups of polyamide 6 and polycarbonate, respectively. The ternary blends with PPO (5–10% w/w) have lower thermal stability than PA6/PC blends. This is due to the decrease of miscibility between these polymers and the rise of the diluting effect. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2556–2562, 2001     

Study on toughening effect of maleic anhydride‐grafted‐poly(ethylene‐octene) to EVOH and their compatibility

Blends of poly(ethylene‐co‐vinyl alcohol) (EVOH) with maleic anhydride‐grafted‐poly(ethylene‐octene) (POE‐g‐MAH) were prepared by blending extrusion in order to improve the toughness and flexibility of EVOH. The compatibility behavior of these blends with POE‐g‐MAH content range from 0 to 25 wt% was studied using mechanical, thermal, infrared, and morphology characterization techniques. The mechanical test results showed that POE‐g‐MAH can significantly improve the impact toughness of EVOH with a brittle‐tough transition appeared at the POE‐g‐MAH content of 20 wt%. A huge increase of toughness of the blend was also observed when the POE‐g‐MAH content was increased to 15 wt%. The thermal analysis of the blends demonstrated that the thermal stability of EVOH is improved with the addition of POE‐g‐MAH, adding 20 wt% or more POE‐g‐MAH can effectively decrease the crystallinity of EVOH and greatly improve compatibility between the two components. The existence of esterification between anhydride groups in POE‐g‐MAH and hydroxyl groups in EVOH in melt processing was confirmed using Fourier transform infrared technique. Morphology analysis of the Izod impact fractures has clearly shown the mechanisms for these blends to change from brittle to tough with increasing the POE‐g‐MAH content. POLYM. ENG. SCI., 53:2093–2101, 2013. © 2013 Society of Plastics Engineers     

Crystallization behavior and mechanical properties of polypropylene random copolymer/poly(ethylene‐octene) blends

New polymer blends of polypropylene random copolymer (PP‐R) and poly(ethylene‐octene) (POE) were prepared by melt‐blending process using a corotating twin‐screw extruder. The POE content was varied up to 35%. The toughening efficiency of POE for PP‐R was evaluated by the mechanical properties of the resulted PP‐R/POE blends. The crystallization behavior and morphology of the blends were also studied. Results show that POE acts as nucleation agent to induce the crystallization of PP‐R matrix at higher crystallization temperature. Super‐toughened PP‐R/POE blends (Izod impact strength more than 500 J/m) can be readily achieved with only 10 wt % of POE. The high toughness of PP‐R/POE is attributed to cavitation and shear yielding of matrix PP‐R, as revealed by the morphology studies. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Effect of core‐shell morphology evolution on the rheology,crystallization, and mechanical properties of PA6/EPDM‐g‐MA/HDPE ternary blend

In this article, polyamide 6 (PA6), maleic anhydride grafted ethylene‐propylene‐diene monomer (EPDM‐g‐MA), high‐density polyethylene (HDPE) were simultaneously added into an internal mixer to melt‐mixing for different periods. The relationship between morphology and rheological behaviors, crystallization, mechanical properties of PA6/EPDM‐g‐MA/HDPE blends were studied. The phase morphology observation revealed that PA6/EPDM‐g‐MA/HDPE (70/15/15 wt %) blend is constituted from PA6 matrix in which is dispersed core‐shell droplets of HDPE core encapsulated by EPDM‐g‐MA phase and indicated that the mixing time played a crucial role on the evolution of the core‐shell morphology. Rheological measurement manifested that the complex viscosity and storage modulus of ternary blends were notable higher than the pure polymer blends and binary blends which ascribed different phase morphology. Moreover, the maximum notched impact strength of PA6/EPDM‐g‐MA/HDPE blend was 80.7 KJ/m² and this value was 10–11 times higher than that of pure PA6. Particularly, differential scanning calorimetry results indicated that the bulk crystallization temperature of HDPE (114.6°C) was partly weakened and a new crystallization peak appeared at a lower temperature of around 102.2°C as a result of co‐crystal of HDPE and EPDM‐g‐MA. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Compatibilization of polypropylene/ poly(3‐hydroxybutyrate) blends

Blending polypropylene (PP) with biodegradable poly(3‐hydroxybutyrate) (PHB) can be a nice alternative to minimize the disposal problem of PP and the intrinsic brittleness that restricts PHB applications. However, to achieve acceptable engineering properties, the blend needs to be compatibilized because of the immiscibility between PP and PHB. In this work, PP/PHB blends were prepared with different types of copolymers as possible compatibilizers: poly(propylene‐g‐maleic anhydride) (PP–MAH), poly (ethylene‐co‐methyl acrylate) [P(E–MA)], poly(ethylene‐co‐glycidyl methacrylate) [P(E–GMA)], and poly(ethylene‐co‐methyl acrylate‐co‐glycidyl methacrylate) [P(E–MA–GMA)]. The effect of each copolymer on the morphology and mechanical properties of the blends was investigated. The results show that the compatibilizers efficiency decreased in this order: P(E–MA–GMA) > P(E–MA) > P(E–GMA) > PP–MAH; we explained this by taking into consideration the affinity degree of the compatibilizers with the PP matrix, the compatibilizers properties, and their ability to provide physical and/or reactive compatibilization with PHB. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Compatibilization of PA6/PPO blend with carboxylated poly(styrene) compounds

PA6/PPO 70/30 blends were reactively compatibilized using carboxylated polystyrene (PS) and poly(styrene‐block‐4‐methylstyrene) with various degrees of carboxylation. The high carboxylation of PS (up to about 50%) caused a decrease of dispersed PPO dimensions with a simultaneous deterioration of properties, especially of toughness and elongation. The best mechanical behavior was found for PS with 1% degree of carboxylation and for neat PS. On the other hand, degrees of carboxylation higher than 50% caused an increase in particle size. This was most significant for block copolymers, where a marked change in size and shape occurred, from spherical particles of about 1 μm in size to large, elongated particles about 50 μm long or a similar rough cocontinuous structure. The deteriorated mechanical behavior is tentatively explained by unsuitable properties of the reactively formed compatibilizer and thus of the interface. The enhanced rigidity of highly carboxylated poly(4‐methylstyrene) chains (and its product of grafting with PA6), causing its decreased emulsification ability together with the expected rigid interface, which probably suppresses breakup of the PPO phase, may be responsible for the increase of the dispersed PPO dimensions found. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 80: 2273–2280, 2001