EXPERIMENT 2

THERMOPLASTIC ELASTOMER BLENDS

INTRODUCTION
1.0

Introduction
Thermoplastic elastomer (TPE) is a new polymer which combine the service
properties of elastomer (vulcanized rubber) and also able to be process as
thermoplastic. This combination of properties can be obtained through simultaneous
presence of soft elastic segments (that have high extensibility and low glass transition
temperature, Tg) and hard segments (which have a lower extensibility; a high Tg) and
there are susceptible association to cross-linking .
The toughness of a polymer is described as the ability to resist by absorbing
energy [1] and is therefore a very important material property. Much research in
polymer field aims at improving the toughness of a material and investigates the
mechanisms by which such an improvement can be obtained.
Acrylonitrile-butadiene-styrene (ABS) is a widely used thermoplastic. In ABS,
acrylonitrile causes an improvement in chemical resistance and weatherability,
butadiene has the character of rubber toughness, and styrene offers glossiness and
processability. The compositions of the various components can be controlled to meet
the requirements of a variety of applications. However, the overall mechanical
properties of ABS are lower than those of most engineering plastics, and the heat
distortion temperature of general grades of ABS is lower than 100C (Ping, 1998,
Chin and Hwang, 1987). In order to upgrade the use of ABS, one simple way is to
blend ABS resin with other high performance engineering plastics such as
polycarbonate (PC) [2] .
PC is an important engineering plastic that is widely used since its
development in 1953 and first production in 1960. Polycarbonate-consumption was

1.1 million tons in 1997 and increasing. Its main features are transparency, toughness
and high-temperature stability applied in car-parts (e.g. headlights), glazing, lighting,
housing for electrical equipment, packaging (e.g. milk bottles) or as data-carrier (CD).
To reduce the sensitivity to these conditions, PC is often blended with
acrylonitrile-butadiene-styrene (ABS). This can only be done in applications where
the transparent character of PC is not important. PC/ABS is one of the most
successful commercial polymer blends. First patents date from 1964. This blend
combines the good mechanical and thermal properties of PC and the ease of
processability, notched impact resistance and the sometimes lower price of
ABS.PC/ABS actually is a ternary blend, since ABS itself usually consist of styreneacrylonitrile (SAN) and dispersion of polybutadiene (PB). The properties of such
ternary blend will depend on the structure properties of the components [1].
Blends of PC and ABS have been commercially available for a number of
years. PC can contribute towards improvements in strength, dimensional stability,
heat distortion temperature and impact resistance of the blends. On the other hand,
ABS provides processing advantages, chemical resistance besides cost reduction with
respect to PC. Therefore, the purpose of ABS/PC blends is the modification of
properties and performance with respect to the neat polymers [2].

1.1

Objectives
To prepare and produce of thermoplastic elastomer blends using Single or

Twin Screw Extruder

To analyze the effect of compatibilizer on the properties of thermoplastic
elastomer blends.

CHAPTER II

LITERATURE REVIEW

2.1

Acrylonitrile Butadiene Styrene (ABS Polymers)

2.1.1 General Introduction

Acrylonitrile-butadiene-styrene (ABS) has grown to become one of

the most widely used thermoplastic in the world because of the wide
range of available properties, ease of processing, and a good balance
between price and performance.
The ABS resins have well-balanced set of properties for molding
close dimensional control articles with an outstanding surface finishing
good impact resistance, and metal plating characteristics. ABS resins
belong to a very versatile family of thermoplastic polymers. ABS is
produced by combining three monomers: acrylonitrile, butadiene and
styrene. The chemical structure of these monomers requires each
monomer to be an important component of the ABS resins. Acrylonitrile
contributes heat resistance, chemical resistance, and surface hardness to
the system. The butadiene contributes toughness and impact resistance,
while styrene component contributes processibility, rigidity and strength.
ABS plastics are two-phase systems. Styrene-acrylonitrile (SAN)
forms the continuous matrix phase. The second phase is composed of
dispersed polybutadiene particles, which has a layer of SAN grafted onto
their surface. The binding matrix layer of SAN makes this polymers two
phases compatible [3].

2.1.2 Chemistry

NC

Acrylonitrile

n
Butadiene

Styrene

ABS plastics are two-phase systems. Styrene-acrylonitrile (SAN) forms the

continuous matrix phase. The second phase is composed of dispersed polybutadiene particles,
which has a layer of SAN grafted onto their surface. The binding matrix layer of SAN makes
this polymers two phase compatible [3].
Common types of ABS polymers have an average composition of 21 to 27%
acrylonitrile, 12 to 25% butadiene and 54 to 63% styrene. Acrylonitrile primarily offers
chemical resistance and heat stability, butadiene gives toughness and impact strength and the
styrene commonly provide ABS with balance of clarity, rigidity and ease of processing (Svec
et al., 1990).
Styrene and acrylonitrile can be copolymerized to form SAN copolymers, typically at
a 70/30 ratio of SAN. Like polystyrene, SAN is a clear copolymer, but with the additional
characteristics of higher chemical resistance, better surface hardness and improved toughness
(Pillichody and Kelly, 1990). This copolymer is a commercially significant product, with
major applications in markets such as battery cases, disposable cigarette lighters and house
wares.
ABS polymer systems typically contain between 70 and 90% SAN. In forming the
continuous phases of ABS, the SAN contributes its characteristics of easy processing, high
strength and rigidity, chemical resistance and good surface hardness and appearance [4].

2.1.3 Properties
The properties of ABS polymers are determined by molecular and morphological
parameters, the matrix composition and molecular mass, the type of rubber, the volume ratio
of the rubber to the continuous phase, the rubber particle size, the grafted rubber structure,
and the additive content are also important [5].
Table 2.1 summarized the effects, which will occur under some situations. The
properties of this multi-phase system are also affected by conditions at the interface between
the rubber level is extremely important and the major trade-offs from the increased rubber
level are shown in Figure 2.1.
ABS polymer has low density (1020 to 1060 kgm -1) and the bulk density of the pellet
is also low, usually 500 to 600 kgm-3 (Pillichody and Kelly, 1990). The material is opaque as
a result of the different refractive indices of the two phases. The presence of the polar nitrile
group results in certain affinity of the ABS polymer for water or water vapour. An increase in
the humidity content will lead to complications in processing and to deteroration in some
properties [4]..

Increase molecular

Narrow molecular

Broad molecular

Increase the content

weight of the SAN

Increase resistance to

weight distribution
weight distribution
Improve dimensional Increase heat and

of elastomers
Decrease heat

surface-active

stability

pressure sensitivity

deformation

Decrease in

of the melt
Improve flow

resistance
Increase melt

substances
Impact strength

increase
Suppression of creep

shrinkage
Increase creep

Tensile strength

resistance
Tensile strength

properties

viscosity
Improve the impact
strength
Ageing resistance

increase
increase
decrease
Fluidity decrease
Stiffness increase
Table 2.1 : Effect of molecular characteristics of the elastomer phase and SAN copolymer
forming the matrix (Svec et al., 1990)

Tensile Strength

Impact Strength

Rigidity

Creep strain

Hardness

Melt Viscosity

Heat Resistance

Thermal

Expansion

Figure 2.1 : Major property trade-offs for ABS with increasing rubber level.
(Glenn and Cathleen, 1985)
Medium
High
Very High
Impact
2.1.3.1 Mechanical Properties

Impact

Impact

The overall toughness offered by ABS materials is the prime mechanical property that
INCREASING RUBBER LEVEL
prompts most users to select ABS for their applications. The standard measure of impact
strength of used for ABS is notched Izod impact strength, as measured by ASTM D256A.
Although ABS is notch sensitive, it is much less so than many other polymer, including

polycarbonate and nylon. In addition to good impact strength at room temperature, ABS
retains significant impact strength at very low temperature (Svec et al., 1990). This has led to
the use of ABS in critical low-temperature applications. ABS materials can deform in a
ductile manner over board temperature range and at high strain rates.
Another important characteristic of engineering thermoplastic is their stress-strain
behavior in flexure. As with tensile properties, the flexural strength at yield and flexural
modulus can be used to determine the resistance of a product to short-term loadings (Nobert,
1971). They also useful in comparing the strength and rigidity of the many ABS products [4].

2.1.3.2 Thermal Properties

The critical thermal properties for ABS are heat distortion, coefficient of linear
thermal expansion, thermal endurance, thermal conductivity, and specific heat. The most
common measure of heat distortion is the deflection temperature under load as measured by
ASTM D648. High-heat ABS, ABS/Polycarbonate (PC) alloys, and ABS/styrene-maleic
anhydride (SMA) alloys all extend applications of ABS into the temperature up to 110 oC at
1.8 MPa for short-term exposures (Jenker and Koln, 1983).
In general, plastics have significantly higher thermal expansion coefficients than
metals. Consequently, in applications where parts are constrained, thermal stresses must be
accommodated in part design or expansion may induce failure in the part. This property is
especially important in ABS products designed for electroplating (Moh et al., 1997).
The thermal properties of ABS polymers are characterized mainly by the glass
transition temperature, Tg. An increase in temperature of the material leads to a decrease in

the tensile strength and increase in the ductility and toughness. However, the modulus of
elasticity in tension decreases (Svec et al., 1990) [4].

2.1.3.3 Rheology
Factors influencing melt flow behavior of ABS include (Moh et al., 1997) :
1. The presence of the grafted rubber domains, their weight fraction, graft to
rubber ratio, particle size distribution;
2. The composition, molecular weight and molecular weight distribution of the
matrix;
3. Additives, ie, lubricants, stabilizers, fillers, pigments, etc;
4. Residual components from the polymerization process; and
5. Water.
The presence of the grafted rubber increases viscosity; the viscosity effect increases
with decreasing shear rates and increasing rubber content. Residual volatile
components and lubricants can function as diluents to reduce viscosity. It has been
suggested that their influence on viscosity may depend on whether such materials
preferentially reside in the rubber or matrix phase (Glenn et al., 1985) [4].

2.1.3.4 Chemical Resistance

The chemical resistance information has been obtained from numerous sources and it
is primarily based on plastic material test specimens that have been immersed in the chemical
(not combination of chemicals) and on field experience. Under no circumstances is to be
assumed that a mixture of individually acceptable chemicals may be safely used with ABS or
any other products.

The effect of the combination of chemical on the ABS components has to be assessed
in conjunction with other factors that have a significant impact upon the lifecycle of the
system i.e. temperature, internal pressure, flexural stresses, cyclic loads etc. Any chemical
attack is increased when temperature or stress are increased or when temperature or stress are
varied. Table 2.2 shows the reference for the chemical solvents that may affect the resistance
[6].
CHEMICAL

RESISTANCE
Weak acids
Good resistance
Strong acids
Limited resistance
Weak alkalis
Good resistance
Strong alkalis
Good resistance
Aggressive soils
Excellent resistance
Metal salts
Good resistance
Sea water
Excellent resistance
Aromatic hydrocarbons
Poor resistance
Organic solvents
Poor resistance
Table 2.2 : Reference Chemical Resistance

2.1.4 Processing

2.1.4.1 General Processing

ABS material can be processed by injection molding, extrusion, blow molding.
However, injection molding and extrusion account more than 93% of all ABS material usage.
ABS polymers process very easily and can be fabricated into very complex parts. ABS
requires significantly lower processing temperatures and is less sensitive to processing
conditions (Brisimitzakis, 1994) [4].
2.1.4.2 Extrusion

An extruder with minimum L/D ratio of 24:1 is recommended to ensure a uniform

mixing and melt temperature over the die. A screen pack consisting of a 20-40 mesh
combination is recommended. Single or two twin screw are suitable. However, the latter part
is preferred since it also aids in devolatilization and results in an improved extrudate quality
(Pillichody and Kelly, 1990) [4].

2.1.4.3 Injection molding

ABS polymers can be processed in all types of injection molding equipment, but
optimum results are obtained with reciprocating screw machines since it provides more
uniform melt and higher available pressure. Processing temperatures range from 177 to
288oC, depending on the specific grade. Injection pressure of 69 t0 138 MPa and clamp
pressure of 281 to 422 kg/cm2 of projected part surface are usually sufficient. Screw having a
length to diameter (L/D) ratio of 20:1 is recommended (Glenn and Cathleen, 1985).
2.1.5 Advantages and Disadvantages
ABS, being copolymerized from three different monomers, has high
impact strength and competes well with polypropylene although it is more
expensive [4]. Its good dimensional stability [3], it replaces die-cast metal
components and can be electroplated. ABS is excellent for vacuumforming and blow-moulding

for the production of articles such as fire

extinguishers, bus wheel arches, industrial containers, refrigerators shells

and protective helmets. It has good impact resistance (toughness) and
rigidity properties. Basically, ABS is preferred for its favourable balance of
high gloss, colourability, processability and price.

The balances of properties which are exhibited by ABS are not found
in any other plastic material. ABS material can be classified as a
lightweight plastic material due to low creep [3].
Besides the advantages, the material has also a number of
limitations. The disadvantages are as follows:
1.
2.
3.
4.
5.

Limited chemical resistance to hydrocarbon and concentrated acids and alkalis.

Low dielectric strength
Only low elongation available
Low continuous service temperature
It is easily burn with high flammability value.

2.1.6 Applications
Their broad property envelope, wide processing latitude, and favourable price and
performance balance has allowed AES based to participate in a wide variety of markets [4].
ABS may be processed into end products by most thermoplastic processing methods
such as injection and compression moulding, extrusion, blow moulding. Other operations
such as vacuum forming vapour metallizing, plating, hot stamping and painting may also be
carried out.
Different grades of ABS are available inter-nationally. Gradewise applications of ABS
have been depicted in the following table [7].

Sr.
1.

Grade no.
High Impact Grades

Applications
Travelling bags, Helmets, Furniture, Sports Goods,

2.

Medium Impact Grades

Automotive Components
Radiator and Air Conditioner grills, Heavy duty domestic

3.

Electroplating Grades

appliances, Control panels

TV and Radio knobs, Bathroom fittings, Refrigerator
handles, Name plates, Wheel caps, Clock rings, Canopies,

4.

High Flow Grades

Flash guns, Torch lights etc.

Housing for domestic appliances and office equipment,

Cabinets of TVs, Radios, Wall clocks, Tape recorders and

High Heat Resistant Grades

Car stereos.
Automobile components, Housing for electrical heaters &

Transparent Grades

dryers
Used in areas where high transparency & good impact

7.

Impact Modifier Grades

strength is required
Modifier to PVC compounding industry, covering all types

8.

Glass Filled Grades

of formulations-rigid, semi-flexible, clear and opaque

Used in applications requiring a very high flexural

5.
6.

strength, stiffness, maintaining the impact and tensile

9.

2.2

strength
Extrusion Grades
Refrigerator linings and luggage
Table 2.3 : ABS GRADEWISE APPLICATIONS

Polycarbonate (PC)

2.2.1 General introduction and Historical Background

Polycarbonate (PC), was first developed in 1953 by Bayer in Germany, and General
Electric in the US independently. LEXAN is its most popular trade name. PC is a heterochain
polymer featuring high performance that comprise the family of engineering
thermoplastics. PC is an excellent material choice as it is not just high-performing but also
can be recycled and be produced in an eco-friendly manner.
A PC molecule includes a Bisphenol A part and a carbonate group. Bisphenol A has
two aromatic rings rendering PC high strength. It does not crystallize easily due to the
Bisphenol group. The polymer attains its transparency due to this amorphous structure. The
characteristic high glass transition temperature (Tg = 145oC) of PC is caused by the minimal
molecular rotation about the bonds [8].

O
CH3

O
n

O
CH3
Bisphenol A

Carbonate

2.2.1 Chemistry and Manufacturing

2.2.1.1 Chemistry
PC is most often synthesized from Bisphenol A and phosgene by a step-growth
polymerization in which Cl- ions are eliminated every time the monomers react. This kind of
step-growth polymerization is often called a condensation process [8].
1. Polymerization Steps
- The Bisphenol A group are reacted with proton acceptors such as NaOH to
obtain the polymerization functional groups.
OH

HO

+
H3C

CH3

2 Na OH
H3C

CH3

2 Na

H2O

Bisphenol A

Sodium
hydroxide

Disphenolate ion of
bisphenol A

- The deprotonated Bisphenol A reacts with Phosgene and a catalyst at

temperatures between 25 and 35oC. this way, a Polycarbonate monomer is
formed, and the catalyst (often times Pyridine), is eliminated along with
the anion.
O

O
O

+
H3C

Phenolate ion end

Cl

Cl

CH3

H3C

phosgene

CH3

chloroformate end on bisphenol A

on bisphenol A
- In order to react more Bisphenol A and phosgene into the chain, chloride
anions are always eliminated
O
O

O
O

H3C

CH3

Cl
H3C

CH3

Cl

Chloroformate end of polymer

disphenolate ion of bisphenol A

CH3
O
H3C

O
CH3

O
H3C

Polycarbonate polymer being extended

2.2.1.2 Manufacturing of PC
Polycarbonate is transformed from pellets into the desired shape for its intended
application by melting the polycarbonate and forcing it under pressure into a mold or die to
give it the desired shape depending on the application. This process is repeated thousands of
times.
In the extrusion process, the molten PC is passed through a die that gives the material
its final shape. After this, the melt is cooled rapidly. Long pipes and sheets are created by this
process.
In the molding process, the PC melt is pressed into a mold with defined shape of the
final product. The melt is then cooled inside the mold. This process is ideal for specific parts
such as automotive and computer parts [8].

Cl

2.2.2 Properties
2.2.2.1 Physical and Mechanical Properties
Polycarbonate is a polymer which, when un-crystallized, has excellent transparency.
When thick, it has a slight yellowish tint. The index of refraction of transparent and colorless
PC is very high, 1.584. the industrial grades of PC have molecular weights on the order of
20,000 to 50,000 g.mol-1. The relative rigidity of the chain causes high viscosity in the liquid
state.
Polycarbonate has a vitreous transition temperature of about 150 oC and consequently
it is to be used almost exclusively in the vitreous range (great rigidity). At ambient
temperature (between T = 80oC and Tg = 150oC). PC is ductile, which explains in part its
very good resistance to shock. Polycarbonate has polymers [9].
-

Little elongation relative to rupture,

Excellent resistance to shock even cold,
A wide temperature range for use (up to 135oC)

sterilization

possible.

2.2.2.2 Chemical Properties

PC absorbs only small quantities of water (<0.6%) and its mechanical properties are
not affected by it. PC can be used for making objects frequently washed with hot or sterilized

water, but a long period of time in hot water (0>60 oC) causes a decomposition resulting in a
drop in shock resistance.
PC is not attacked by diluted mineral and organic acids. It is insoluble in aliphatic
hydrocarbons, ether and alcohol. It is partially soluble in numerous halogenous hydrocarbons.
PC is attacked by strong bases (ammonia). PC is fairly stable in the presence of ozone.
Stability in UV light is not exceptional and PCs turn yellow fairly quickly. Suitability for
contact with food and physiological innocuousness. PC is recognized as being suitable for
making objects in contact with food. Certain grades are approved for medical use. PCs can be
sterilized with steam [9].

2.2.2.3 Electrical Properties

Polycarbonate has good insulating properties little affected by variations in
temperature or humidity.

2.2.2.4 Thermal Properties

PC is practically self-extinguishable. Resistance to fire, rated per UL94, ranges from
HB to V0-V2 according to type, wall thickness and stabilization.

2.2.2.5 Dimensional Properties

Polycarbonate, as all un-crystallized polymer, offers limited retraction when molded
(<0.6%):

Its low absorption of humidity gives it good dimensional stability in a

humid atmosphere;
PC has good creep resistance, especially when reinforced with fiber glass.

2.2.3 Applications
Since PC has an excellent strength, it is suited for shatter resistant or bulletresistant glass applications. Its relatively low weight in comparison to other high-strength
materials and its high ductility make it attractive to be used in lenses and windows. It has
been also used as a flame retardant and an electrical insulator. PC finds extensive use in
manufacture of DVDs, CDs, automotive, cell phone and laptop components. It can be used
in small filters for the extrusion of small particles.

2.3

Compatibilizer
In most cases, it is necessary to add a compatibilizing agent to strengthen the

interface. In basic research, the preferred compatibilizing agent is a di-block copolymer, with
one block soluble in one phase and the other block soluble in the other phase. The block
copolymer tends to locate at the interface. This creates primary covalent bonds across the
interface and thus strengthens it. In commercial practice, the compatibilizing agent is usually
a graft copolymer, with a backbone soluble in one phase and side chains soluble in the other
phase; this is not as theoretically satisfying, but it is usually easier and more economical to
make and appears to work perfectly well in practice. In some cases, the graft copolymer is
made separately and then added to the poly-blend during compounding; in other cases, it may
be formed directly during compounding by reactive processing [11].

2.3.1 Styrene Acrylonitrile (SAN)

SAN is a copolymer of styrene and acrylonitrile. It offers superior mechanical
properties, chemical resistance and heat resistance in comparison with general purpose
polystyrene resin. Surface gloss, dimensional stability, mechanical strength and electrical
properties of SAN are superior to GPPS, and it can be more easily processed than acrylic
resins. In general, due to nature of the molecular structure, SAN resin tends to be yellowish
and lose the transparency after injection molding.
Styrene based materials offer unique characteristics of durability, high performance,
versatility of design, simplicity of production, and economy. They can provide excellent
hygiene, sanitation and safety benefits. And many of these products otter very good insulation
qualities and the ability to be recycled where collection systems are made available, making
sound use of our normal resources. In many cases, styrene helps creates products that are
very unique, and for which there are few effective substitutes [12].

2.4

Polymer Blends
The concept of physically blending two or more existing polymers to obtain new

products (polymer blends) or for problem solving is now attracting widespread interest and
commercial utilization. Polymer blends are often referred to by the contraction polyblends

and sometimes as alloys to borrow a term from metallurgy (Modern Plastic Magazine,
1994). The need for improved balance of properties and the potential ability of polymer
blends to satisfy this need have converged in the development of polymer blending as a major
area for rigorous growth in the past several years. Properties of plastics that have most often
been improved by polymer blending include processability, tensile strength, ductility, impact
strength, abrasion resistance, heat deflection temperature, low-temperature flexibility, flame
retardancy, and environmental stress-crack resistance [4].

2.4.1 ABS Blends

ABS is itself a blend of PB and SAN, but can be further blended with other materials
and thus the scope of possible applications is broadened. Commercial blends with ABS are
given in Table 2.3 (Adam et al., 1993) and some of these will be discussed in more detail
below [4].
Blend

PC/ABS

Key Properties
Heat resistance, low
temperature impact,
processability, ease of flame
retarding
Impact strength and

PVC/ABS

Nylon/ABS

TPU/ABS

PBT/ABS

Polysulphone/ABS

Application

Growth Rate

Automotive, computer housing,

lawn and garden, power tools,

9%

recreational vehicles
Electrical components,

toughness, flame retardance,

appliances, business machine

UV stability, processability
High impact, chemical

housings, housewares
Automotive body panels and

resistance, low moisture

underhood components, vacuum

sensitivity
Chemical and abrasion

cleaner housing

resistance, low temperature

Auto bumper fascia

toughness
Processability, impact

Lawn and garden equipment,

strength, heat and chemical

small appliances, fluid

resistance
Processability, low cost, heat

engineering industry
Appliances, auto window handles,

resistance, can be plated

faucets, food trays

Table 2.4 : Blends with ABS (Adam et al., 1993)

12-18%

7%

8%

2.4.2

Polycarbonate/ABS Blends
The second class of alloy is produced through blends made with polycarbonate (PC).

Nearly all PC/ABS is used in automotive and business machine applications, with a small
amount in lawn and garden equipment, power tools and recreational vehicles. PC/ABS
properties and price are intermediate between those of the more expensive PC and the less
expensive ABS. The blends/alloys of PC/ABS provide heat resistance as well as low
temperature impact strength and processability. ABS improve the processability and reduced
cost whereas the PC provides the heat resistance and toughness and impact, higher tensile
properties and improved ease of flame retarding (Bonner and Hope, 1993). These alloys
exhibit excellent toughness, good heat distortion and high rigidity (Glenn and Cathleen,
1985) [4].
The commercialization of PC began in 1958; the production of the PC/ABS blends
started on 1977. The addition of ABS to PC minimizes its drawbacks without affecting its
superior mechanical properties, and also generates other useful characteristics, such as
glossiness and low temperature toughness. A number of patents concerning these blends have
been issued in the past, but the scientific knowledge about their behaviour is still limited
owing to the complexity of the system. The blends consist, in fact, of four polymeric species
and three phases, their morphology depending on a variety of factors: molecular
characteristics of the components, ABS composition, blend composition, rheological
properties, processing conditions, thermal treatments, etc. PC and ABS are fairly similar in
polarity, and might be compatible with each other; the ABS grafted rubber (butadiene)
particles chains would remain insoluble, but firmly bonded by their styrene-acrylonitrile sidechains, producing good physical properties [10]. Assuming this fundamental basis for semi-

compatibility, it is interesting to determine simultaneously the behavior of the modulus and

the impact strength of the blends versus the PC content.

CHAPTER III
METHODOLOGY

3.1 Materials and Blend Preparation

The material used in this experiment were the following:

Polycarbonate, PC
Acrylonitrile-Butadiene-Styrene (ABS)
Poly(styrene-co-acrylonitrile) (SAN)

Materials

Polycarbonate (PC)

Ratio blend PC:ABS

Ratio blend PC:ABS with

without SAN (%)

SAN (%)

70

30

70

30

30

70

30

70

Acrylonitrile Butadiene
Styrene (ABS)
Table 3.1 : Ratio of polymer blend
The equipment are following :
-

Twin Screw Extruder

Hot press
Instron Machine
Dumbbell Cutter

3.2 Blend Preparation

1. Two different polymer blend systems are prepared which is PC/ABS with bend ratio
of 30:70 and 70:30 for each blend system for with and without compatibilizer at 10%
of SAN.
2. The material were dried-mixed in small cups before being feed into the extruder
3. Each of the blend systems were mixed through melt blending in a twin screw extruder
at a blend temperature of 280oC and with the screw speed of 70rpm.
4. The blends were extruded into a water bath, and the extruded strands were pelletized.
5. The pellets were then dried in the oven overnight.
6. They were compression moulded into sheet specimens by using hot press of about
2mm thickness for tensile testing.
7. The compression molding were set at temperature of 280oC to compress all the
blends.

CHAPTER IV

RESULT AND DISCUSSION

4.1

Result

Polymer
Blend
PC : ABS
without SAN
PC : ABS
without SAN
PC : ABS
with SAN

Mean
Ratio blend

Tensile strength

Break Elongation

Modulus of

(MPa)

(%)

Elasticity (MPa)

30/70

23.52

2.00

1537.20

70/30

54.81

7.85

1778.4

30/70

59.27

4.90

2103.16

Table 4.1 : Tensile result of different ratio blends

PC : ABS

70/30
60.29
12.25
with SAN
4.1.1 Effect of PC Content on Tensile Strength and Young Modulus

1892.23

Both tensile strength and modulus of elasticity increased with increasing PC content
in the ABS/PC blend (Figure 4.1.1 and Figure 4.1.1.2). From Figure 4.1.1, it was observed
that the tensile strength increased almost linearly with the increasing of PC ratio in the
ABS/PC blends. Similar to the observations, it was reported in Wei and Hwang (1999) study
which stated the tensile strength increased with the increasing PC contents in ABS/PC blends
[4]. In addition, Young Modulus showed a significant improvement from 1537.20 MPa to
1778.40 MPa when 40 wt% PC was added into the blends as compared to the ABS. The
Figure 4.1.1.2 as shown below that determine the effect of Modulus of polymer blend ratio.

Tensile Strength (Mpa) vs polymer blend ratio

70.00
60.00
50.00
40.00
Tensile Strength (MPa)

Tensile Strength (Mpa)

30.00
20.00
10.00
0.00
PC/ABS without SAN (30/70)
Polymer Blend Ratio

Figure 4.1.1 : Effect of Blend Ratio on Elongation at Break of ABS/PC blends

Modulus of elasticity (Mpa) vs polymer blend ratio

2500.00

2000.00

1500.00
Modulus of elasticity (Mpa)

Modulus of Elasticity (MPa)

1000.00

500.00

0.00
PC/ABS without SAN (30/70)
Polymer Blend Ratio

TABLES OF CONTENTS

CHAPTER TITLE

PAGE

Figure 4.1.1.2 : Effect of Blend Ratio on Modulus of Elasticity ABS/PC blends

4.1.2 Effect of PC Content of Elongation at Break

Figure 4.1.2 shows the effect of PC content on the elongation at break for ABS/PC
blends. It was found that, the elongation at break shows an increment of 5.85% between 30
wt% to 70 wt% PC. Generally, the elongation at break for ABS/PC blends increased with the
increasing of PC contents in the blends.

Breaking Elongation (%) vs polymer blend ratio

14.00
12.00
10.00
8.00
Breaking Elongation (%)

Breaking Elongation (%)

6.00
4.00
2.00
0.00
PC/ABS without SAN (30/70)
Polymer Blend Ratio

Figure 4.1.2 : Effect of Blend Ratio on Elongation at Break of ABS/PC blend

4.1.3 Effect of SAN on the ABS/PC blends

Theoretically, in ABS morphology, the butadiene rubber particles are dispersed in the
SAN phase. However, as PC content increased, it gradually became the continuous phase in
the blend whereas ABS particles were dispersed in the PC continuous phase [4]. The result
shows that the increasing of tensile strength from 59.27 MPa to 60.29 MPa with 40 wt% of
PC blends into ABS. For the modulus of elasticity, the value were decrease to 210.93 MPa as
the increasing amount of PC blend added into the ABS with compatibilizer. When the
addition of SAN into the ABS/PC blends, it will offers high tensile strength, highest impact
resistance,

unfortunately, the modulus of elasticity will decrease. These statement can be

proved in Figure 4.1.1.2.

CHAPTER V

CONCLUSION

5.1 CONCLUSION

The objective of the experiment is to analyse the effect of compatibilizer on the

properties of ABS/PC blend. Based on the result, both tensile strength and modulus of
elasticity increased with the increasing of PC content in ABS/PC blend. With the increasing
of PC content in ABS/PC blends, elongation at break for ABS/PC blends generally increased.
Furthermore, with the addition of the compatibilizer such as SAN will gives an effect on
ABS/PC blend. Although the tensile strength and elongation at break shows an increment
value, the modulus of elasticity will decrease as the content in the blend will have continuous
phase.

REFERENCES

[1]

J.P.F. Inberg (2001,April). Fracture of polycarbonate/ABS Blends. University of Twente, The

Netherlands
[2]

W. Yean Jwu (2005,Aug,11).Mechanical Properties of High Impact ABS/PC BlendsEffect of Blend Ratio. Department of Polymer Engineering, Faculty of Chemical and
Natural Resources Engineering. Universiti Teknologi Malaysia, 81310 UTM Skudai,
Johor Bahru.

[3]

E. Alfredo Campo. Industrial Polymer.

[4]

PM Dr Azman Hassan, PM Dr Shahrir Hashim, C.Sau Yen (2007, March).

Mechanical, Chemical and Flammability Properties of ABS/PVC Blends. JABATAN
KEJ. POLIMER, FAK. KEJ. KIMIA DAN KEJ. SUMBER ASLI, UTM SKUDAI,
JOHOR.

[5]

Acrylonitrile-Butadiene-Styrene (ABS) Polymer (2007, Dec)

[6]

Spec of ABS Material (2005,June)

[7]

Manufacturing of ABS (2004, June)

[8]

Carlos F. Buitrago (2005,Nov,30). Polycarbonate (PC), Introduction to Polymers

[9]

Marie De Sausa (2010,Aug,11). Polycarbonate-PC

[10]

L. A. Utracki and B. D. Favis, Polymer Alloys and Blends, In: P. N. Cheremisinoff,

Ed., Handbook of Polymer Science and Technology, Marcel Dekker, Inc., New York,
1989, pp. 121-201.

[11]

Mc.Graw Hill, Plastic Additives, Access Engineering

[12]

(2008,Nov), Styrene Acrylonitrile (SAN)

TABLES OF CONTENTS

CHAPTER

TITLE
TITLE PAGE
LIST OF TABLES
LIST OF FIGURES

INTRODUCTION
1.1 Introduction
1.2 Objectives

II

LITERATURE REVIEW
2.1 Acrylonitrile Butadiene Styrene (ABS)
2.1.1 General Introduction
2.1.2 Chemistry
2.1.3 Properties
2.1.3.1 Mechanical Properties
2.1.3.2 Thermal Properties
2.1.3.3 Rheology
2.1.3.4 Chemical Resistance
2.1.4 Processing
2.1.4.1 General Processing
2.1.4.2 Extrusion
2.1.4.3 Injection Molding
2.1.5 Advantages and Disadvantages
2.1.6 Applications
2.2 Polycarbonate (PC)
2.2.1 General Introduction and Historical
Background
2.2.2 Chemistry and Manufacturing
2.2.2.1 Chemistry
2.2.2.2 Manufacturing
2.2.3 Properties
2.2.3.1 Physical and Mechanical Properties
2.2.3.2 Chemical Properties
2.2.3.3 Electrical Properties
2.2.3.4 Thermal Properties
2.2.3.5 Dimensional Properties
2.2.4 Applications
2.3 Compatibilizer
2.3.1 Styrene Acrylonitrile (SAN)
2.4 Polymer Blends
2.4.1 ABS Blends
2.4.2 PC/ABS Blends

III

METHODOLOGY

PAGE

3.1 Material
3.2 Blend Preparation
IV

RESULT AND DISCUSSION

4.1 Result
4.1.1 Effect of PC Content on Tensile Strength and Young
Modulus
4.1.2 Effect of PC Content of Elongation at Break
4.1.3 Effect of SAN on ABS/PC blends

CONCLUSION
5.1 Conclusion
REFERENCES

LIST OF TABLES

TABLE No.
2.1
2.2
2.3
2.4
3.1
4.1

TITLE
Effect of molecular characteristics of the elastomer phase

PAGE

and SAN copolymer forming the matrix (Svec et al., 1990)

Reference Chemical Resistance
Abs Gradewise Applications
Blends with ABS (Adam et al., 1993)
Ratio of polymer blend
Tensile result of different ratio blends

LIST OF FIGURES

FIGURE No.

TITLE

PAGE

2.1

Major property trade-offs for ABS with increasing rubber

level. (Glenn and Cathleen, 1985)

4.1.1

Effect of Blend Ratio on Elongation at Break of ABS/PC

blends
Effect of Blend Ratio on Modulus of Elasticity ABS/PC
blends
Effect of Blend Ratio on Elongation at Break of ABS/PC
blend

4.1.1.2
4.1.2