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Initial mechanisms of dispersion of core‐shell impact modifiers in a polymer matrix

Core‐shell impact modifiers are effective toughening agents for many thermoplastics. In order to achieve optimum performance, agglomerates of these particles must be dispersed and the individual submicron particles well distributed within the polymer matrix. The focus of this paper is a description of the initial mechanisms of dispersion during compounding of core‐shell impact modifiers into polymer matrices. Model experiments were conducted with acrylic‐based modifiers in a poly(methyl methacrylate) matrix by using a batch intensive mixer. Based on the observed morphologies at numerous mixing times, a qualitative description of the mechanism is developed. Significant structural changes occur in all three of the classical processing regimes: solids conveying, melting, and melt flow. Differences in the form of modifier addition, pellet or powder, are explored. The degree of fill of the mixer is found to have a critical effect on the dispersion mechanism.