Electrically conductive,melt‐processed ternary blends of polyaniline/dodecylbenzene sulfonic acid,ethylene/vinyl acetate,and low‐density polyethylene

Although polyaniline (PANI) has high conductivity and relatively good environmental and thermal stability and is easily synthesized, the intractability of this intrinsically conducting polymer with a melting procedure prevents extensive applications. This work was designed to process PANI with a melting blend method with current thermoplastic polymers. PANI in an emeraldine base form was plasticized and doped with dodecylbenzene sulfonic acid (DBSA) to prepare a conductive complex (PANI–DBSA). PANI–DBSA, low‐density polyethylene (LDPE), and an ethylene/vinyl acetate copolymer (EVA) were blended in a twin‐rotor mixer. The blending procedure was monitored, including the changes in the temperature, torque moment, and work. As expected, the conductivity of ternary PANI–DBSA/LDPE/EVA was higher by one order of magnitude than that of binary PANI–DBSA/LDPE, and this was attributed to the PANI–DBSA phase being preferentially located in the EVA phase. An investigation of the morphology of the polymer blends with high‐resolution optical microscopy indicated that PANI–DBSA formed a conducting network at a high concentration of PANI–DBSA. The thermal and crystalline properties of the polymer blends were measured with differential scanning calorimetry. The mechanical properties were also measured. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 3750–3758, 2004     

Thermal lensing in poly(vinyl alcohol)/polyaniline blends

Nonlinear optical properties of poly(vinyl alcohol) (PVA)/polyaniline (PAni) blends were measured with the single‐beam Z‐scan technique with Fourier analysis. The results obtained with continuous wave (cw) excitation indicated that the self‐phase modulation had a thermal origin. Besides the Z‐scan technique, we also employed the time‐resolved mode‐mismatched thermal lens (TL) technique to obtain the temperature coefficient of the optical path length, ds/dT, and the thermal diffusivity coefficient, D, for the specific concentrations used in our blends. ds/dT varied between ?0.8 and ?1.0 × 10^?4 K^?1, whereas the thermal diffusivity varied between 1.0 and 1.3 × 10^?3 cm²/s. The TL technique was further used to study the aging of the blends as they were heated to 90 °C. Unlike the electrical conductivity of PAni films, which presented a strong dependence on the doping level, the thermooptic properties presented only a slight variation with doping. This feature indicated that the PVA/glutaraldehyde network made the main contribution to the thermooptic properties (D and ds/dT) in the PAni blends. Similarly, dimethyl sulfoxide as a solvent determined the thermooptic properties of PAni solutions. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 1949–1956, 2002     

Synthesis and characterization of epoxidized polybutadiene/polyaniline graft conducting copolymer

In this article the synthesis and characterization of an elastomeric conducting material, obtained by grafting polyaniline (EB) on commercial cis‐1,4‐polybutadiene (PB), are described. PB was first partially epoxidized in chloroform solution using meta‐chloroperbenzoic acid (MCPBA). The conducting polymer was then grafted to the activated polybutadiene (EPB) via the aminolysis reaction between the polyaniline NH₂ terminal groups and the oxirane rings. The material so obtained (EPBPAN) and the epoxidized intermediate product were characterized by ¹H NMR, ¹³C NMR, Fourier transform infrared, and ultraviolet–visible spectroscopy, thermal and mechanical analysis, and electrical conductivity measurements. The effect of the sample deformation on conductivity also was analyzed. The HCl doping of the EPBPAN film induced crosslinking reactions, generated by the acid cleavage of unreacted oxirane groups. The electrical conductivity of the doped material reached values of about 10^?5 Ω^?1 cm^?1. The key characteristics of our elastomeric conducting material are its simple synthesis, its starting as a commercial product, and the solubility of its undoped form in a common low‐boiling organic solvent like chloroform. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3082–3090, 2004     

Polyaniline/thermoplastic polyurethane blends: Preparation and evaluation of electrical conductivity

Conducting polymer blends whose undiluted components have different properties are promising materials for specific applications and have attracted interest in recent years. The aim of this study was to obtain and evaluate the electrical conductivity of polyaniline doped with dodecylbenzenesulfonic acid (PAni.DBSA)/polyurethane thermoplastic (TPU) blends. The PAni.DBSA was synthesized from DBSA-aniline (DBSAn) salt through an emulsion polymerization in tetrahydrofurane (THF) or in the presence of polyurethane thermoplastic solution, resulting in pure PAni.DBSA or PAni.DBSA/TPU blends. Blends of PAni.DBSA/TPU were also prepared through casting, at room temperature, after dissolving both components in THF as a common solvent. The insulator-conductor transition was very sharp and the percolation threshold was lower than 2.7 wt% of PAni.DBSA. The electrical conductivity of PAni.DBSA/TPU blends, prepared by both methods, reached maximum values at a PAni.DBSA concentration of 40 wt%, close to the value observed for the undiluted conducting polymer. However, for a PAni.DBSA content lower than 30 wt%, the electrical conductivity was dependent on the blend preparation method. Blends were characterized by infrared spectroscopy, thermogravimetric analysis (TG) and optical microscopy. The electrical conducting characteristics of the PAni.DBSA/TPU blends prepared using different procedures indicate a high potential for their successful application in electrical processes.     

Influence of doped polyaniline on the interaction of Pu/PAni blends and on its microwave absorption properties

In this work, the influence of polyaniline (PAni) doped with both camphorsulfonic acid (PAni‐CSA) and dodecylbenzenesulfonic acid (PAni‐DBSA) on polyurethane (PU)/PAni blends was studied by rheological and morphological analyses. The effect of doped polyaniline on the attenuation of incident microwave radiation, in the frequency range from 8.0 to 12.0 GHz, was also investigated. The complex viscosity (η*) of PAni‐DBSA blends is observed to vary more significantly as a function of resting time than PAni‐CSA blends. This behavior is attributed to a better dispersion of PAni particles into the matrix on account of the presence of smaller agglomerates, as observed by optical and electron microscopy. However, this behavior has not been determinant on microwave absorption by the blends, with those that contain PAni‐CSA showing higher attenuation values. Copyright © 2007 John Wiley & Sons, Ltd.     

Processing, characterization and properties of conducting polyaniline-sulfonated SEBS block copolymers

Incorporation of polyaniline (PAni) into thermoplastic elastomers can be used to produce materials that potentially combine the good mechanical properties and processability of thermoplastic elastomers with electrical, magnetic and optical characteristics of PAni. In this work, a polystyrene-block-poly(ethylene-ran-butylene)-block-polystyrene copolymer (SEBS) was chemically modified by grafting a sulfonic group onto the chain backbone in order to promote higher levels of compatibility between the thermoplastic elastomer and polyaniline. The sulfonation process was performed by reacting SEBS with acetyl sulfate. Infrared spectroscopy and titration were used to monitor the amount of sulfonic groups successfully grafted on SEBS. Mechanical tests performed in sulfonated SEBS showed that sulfonation levels lower than 15% did not reduce substantially the mechanical properties of SEBS. PAni doped with dodecylbenzenesulfonic acid (PAni·DBSA), used in the preparation of the blends, was prepared by the “in situ doping polymerization” method. PAni·DBSA was then blended in solution with SEBS having different levels of sulfonation. The introduction of sulfonic group into the structure of SEBS improved coulombic interactions between the phases in the blend and enhanced compatibility. As a consequence, higher values of electrical conductivity (measured by the four-probe method) were achieved in blends with sulfonic groups grafted onto polymer chains. Concentrations as low as 20 wt% of PAni were able to lead to electrical conductivities of PAni·DBSA/sulfonated SEBS blends close to 1.2 S/cm. Optical micrographs of the blends showed that PAni·DBSA/sulfonated SEBS microstructure is composed of a very disperse group of small conducting particles. This type of microstructure would then be responsible for the enhanced electrical conductivity and low percolation threshold of PAni·DBSA/sulfonated SEBS, when compared to PAni·DBSA/SEBS blends.     

Effect of preparation method on nanoscopic structure of conductive SBS/PANI blends: Study using small‐angle X‐ray scattering

Small‐angle X‐ray scattering (SAXS) studies of electrically conductive blends based on polyaniline–dodecylbenzenesulfonic acid (PANI–DBSA)/styrene–butadiene–styrene (SBS) triblock copolymer were performed to investigate the influence of the blend preparation procedure on the nanoscopic structure of the blends. The blends were prepared by mechanical mixing (MM) procedure and by in situ polymerization (ISP) of aniline in the presence of SBS. The results indicate that pure PANI–DBSA presents an extended phase consisting of crystalline islands of nanometric size, with a good spatial correlation between them, embedded into an amorphous PANI phase. This feature was not observed in SBS/PANI–DBSA blends prepared by MM or ISP. In MM blends, the PANI phase is constituted by smaller domains, containing poorly spatially correlated crystalline islands, whereas in ISP blends with low or medium amount of PANI, there is no SAXS peak which could be related to a spatial correlation between PANI crystalline islands. The conductivity of the ISP blends is higher when compared to MM blends because of the higher homogeneity at nanometric scale. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 3069–3077, 2007     

Phase behavior,crystallization, and morphology in thermosetting blends of a biodegradable poly(ethylene glycol)‐type epoxy resin and poly(ϵ‐caprolactone)

Thermosetting blends of a biodegradable poly(ethylene glycol)‐type epoxy resin (PEG‐ER) and poly(?‐caprolactone) (PCL) were prepared via an in situ curing reaction of poly(ethylene glycol) diglycidyl ether (PEGDGE) and maleic anhydride (MAH) in the presence of PCL. The miscibility, phase behavior, crystallization, and morphology of these blends were investigated. The uncured PCL/PEGDGE blends were miscible, mainly because of the entropic contribution, as the molecular weight of PEGDGE was very low. The crystallization and melting behavior of both PCL and the poly(ethylene glycol) (PEG) segment of PEGDGE were less affected in the uncured PCL/PEGDGE blends because of the very close glass‐transition temperatures of PCL and PEGDGE. However, the cured PCL/PEG‐ER blends were immiscible and exhibited two separate glass transitions, as revealed by differential scanning calorimetry and dynamic mechanical analysis. There existed two phases in the cured PCL/PEG‐ER blends, that is, a PCL‐rich phase and a PEG‐ER crosslinked phase composed of an MAH‐cured PEGDGE network. The crystallization of PCL was slightly enhanced in the cured blends because of the phase‐separated nature; meanwhile, the PEG segment was highly restricted in the crosslinked network and was noncrystallizable in the cured blends. The phase structure and morphology of the cured PCL/PEG‐ER blends were examined with scanning electron microscopy; a variety of phase morphologies were observed that depended on the blend composition. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 2833–2843, 2004     

Conducting Elastomer Blends Based on Nitrile Rubber and Pani.DBSA

Electrically conductive elastomer blends based on polyaniline-dodecylbenzene sulfonic acid (Pani.DBSA) and nitrile rubber (NBR) were prepared by polymerization of aniline in the presence of NBR, using a direct, one-step in situ emulsion polymerization method. At the same PAni content, the conductivity of the in situ emulsion-polymerized blends is higher than that of blends produced by mechanical mixing of both components. In addition, a morphology with the presence of PAni in the form of microtubules was achieved by the in situ process. Stronger interaction between the components were also confirmed by Rheological processing analysis (RPA). The vulcanization process decreases the conductivity of the blends prepared by both methods. The in situ polymerized blends also display higher tensile strength and also higher crosslink density     

Phase separation of off‐critical polymer blends of poly(styrene‐co‐maleic anhydride) and poly(methyl methacrylate). II. Morphology and mechanical properties

The effects of the phase‐separation temperature and time on the mechanical properties and morphology of poly(methyl methacrylate)/poly(styrene‐co‐maleic anhydride with 10 wt% ethyl acrylate) (SMA) blends were studied. Two compositions (20/80 and 40/60 w/w SMA/PMMAe) were prepared with a miniature twin‐screw extruder. Compared with those of the miscible blends, the Young's modulus values of the blends increased after the phase separation of the 40/60 SMA/PMMAe blend and within the early stage of spinodal decomposition of the 20/80 SMA/PMMAe blend. The mechanical properties, in terms of the tensile strength at break and the elongation, were better for the miscible blends than for the phase‐separation blends. This was believed to be the result of changes in the composition and molecular reorganization. The changes in the phase‐separating domains of both compositions, as observed by transmission electron microscopy, had no significant influence on the tensile moduli. Detailed studies of the morphology revealed a cocontinuous structure, indicating that the blends underwent spinodal decomposition. A morphological comparison of the two compositions illustrated the validity of the level rule. The growth rate of the droplet size was determined by approximation from the light scattering data and by direct measurements with transmission electron microscopy. The discrepancies observed in the droplet size growth rate were attributed to heat variations induced by the different sample thicknesses and heat transfer during the investigation. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 886–897, 2004     

Polypropylene modified with elastomeric metallocene‐catalyzed polyolefin blends: Fracture behavior and development of damage mechanisms

The fracture behavior and deformation mechanisms of polypropylene modified by elastomeric metallocene‐catalyzed polyolefin blends were investigated under both static and dynamic loading conditions. The fracture toughness was evaluated with the J integral approach. The development of damage mechanisms was studied by the examination of fracture surfaces with scanning electron microscopy and by the examination of single‐edge, double‐notch, four‐point‐bending or low‐impact‐energy fractured samples with optical microscopy. In addition, tensile dilatometry measurements were carried out to determine the nature of the deformation micromechanisms. The fracture behavior and the size and shape of the damage zones were drastically influenced by the elastomeric particles and the imposed constraint. The role of the elastomeric particles was different, depending on the strain rate. Under impact loading, particle pullout and crazing were responsible for the increased fracture toughness of polypropylene. Under quasistatic loading, stable fracture growth was caused by particle cavitation, which promoted ductile tearing of polypropylene before failure continued in an unstable fashion via crazing. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 1075–1089, 2004     

Structure and mechanical properties of talc‐filled blends of polypropylene and styrenic block copolymers

The structure–property relationships of isotactic polypropylene (iPP)/styrenic block copolymer blends filled with talc were examined by optical and scanning electron microscopy, wide‐angle X‐ray diffraction, and tensile‐ and impact strength measurements. The composites were analyzed as a function of the poly(styrene‐b‐ethylene‐co‐propylene) diblock copolymer (SEP) and the poly(styrene‐b‐butadiene‐b‐styrene) triblock copolymer (SBS) content in the range from 0 to 20 vol % as elastomeric components and with 12 vol % of aminosilane surface‐treated talc as a filler. Talc crystals incorporated in the iPP matrix accommodated mostly plane‐parallel to the surface of the samples and strongly affected the crystallization process of the iPP matrix. The SBS block copolymer disoriented plane‐parallel talc crystals more significantly than the SEP block copolymer. The mechanical properties depended on the final phase morphology of the investigated iPP blends and composites and supermolecular structure of the iPP matrix because of the interactivity between their components. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 1255–1264, 2004     

Thermal behavior and intermolecular interactions in blends of poly(3‐hydroxybutyrate) and maleated poly(3‐hydroxybutyrate) with chitosan

The thermal behavior and intermolecular interactions of blends of poly(3‐hydroxybutyrate) (PHB) and maleated PHB with chitosan were studied with differential scanning calorimetry, Fourier transform infrared (FTIR), wide‐angle X‐ray diffraction (WAXD), and X‐ray photoelectron spectroscopy (XPS). The differences in the two blend systems with respect to their thermal behavior and intermolecular interactions were investigated. The melting temperatures, melting enthalpies, and crystallinities of the two blend systems gradually decreased as the chitosan content in the blends increased. Compared with that of the PHB component with the same composition, the crystallization of the maleated PHB component was more intensively suppressed by the chitosan component in the blends because of the rigid chitosan molecular chains and the intermolecular hydrogen bonds between the components. FTIR, WAXD, and XPS showed that the intermolecular hydrogen bonds in the blends were caused by the carbonyls of PHB or maleated PHB and chitosan aminos, and their existence depended on the compositions of the blends. The introduction of maleic anhydride groups onto PHB chains promoted intermolecular interactions between the maleated PHB and chitosan components. In addition, the intermolecular interactions disturbed the original crystal structures of the PHB, maleated PHB, and chitosan components; this was further proven by WAXD results. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 35–47, 2005     

Effect of compatibilizer on morphology and properties of HDPE/Nylon 6 blends

The compatibilization effect of linear low‐density polyethylene‐grafted maleic anhydride (LLDPEgMA) and high‐density polyethylene‐grafted maleic anhydride (HDPEgMA) on high‐density polyethylene (HDPE)/polyamide 6 (Nylon 6) blend system is investigated. The morphology of 45 wt %/55 wt % polyethylene/Nylon 6 blends with three compatibilizer compositions (5 wt %, 10 wt %, and 15 wt %) are characterized by atomic force microscopic (AFM) phase imaging. The blend with 5 wt % LLDPEgMA demonstrates a Nylon 6 continuous, HDPE dispersed morphology. Increased amount of LLDPEgMA leads to sharp transition in morphology to HDPE continuous, Nylon 6 dispersed morphology. Whereas, increasing HDPEgMA concentration in the same blends results in gradual morphology transition from Nylon 6 continuous to co‐continuous morphology. The mechanical properties, oxygen permeability, and water vapor permeability are measured on the blends which confirm the morphology and indicate that HDPEgMA is a better compatibilizer than LLDPEgMA for the HDPE/Nylon 6 blend system. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2019 , 57, 281–290     

Influence of the type of epoxy hardener on the structure and properties of interpenetrated vinyl ester/epoxy resins

The morphology–toughness relationship of vinyl ester/cycloaliphatic epoxy hybrid resins of interpenetrating network (IPN) structures was studied as a function of the epoxy hardening. The epoxy was crosslinked via polyaddition reactions (with aliphatic and cycloaliphatic diamines), cationic homopolymerization (via a boron trifluoride complex), and maleic anhydride. Maleic anhydride worked as a dual‐phase crosslinking agent by favoring the formation of a grafted IPN structure between the vinyl ester and epoxy. The type of epoxy hardener strongly affected the IPN morphology and toughness. The toughness was assessed by linear elastic fracture mechanics, which determined the fracture toughness and energy. The more compact the IPN structure was, the lower the fracture energy was of the interpenetrated vinyl ester/epoxy formulations. This resulted in the following toughness ranking: aliphatic diamine > cycloaliphatic diamine ≥ boron trifluoride complex > maleic anhydride. For IPN characterization, the width of the entangling bands and the surface roughness parameters were considered. Their values were deduced from atomic force microscopy scans taken on ion‐etched surfaces. More compact, less rough IPN‐structured resins possessed lower toughness parameters than less compact, rougher structured ones. The latter were less compatible according to dynamic mechanical thermal and thermogravimetric analyses. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 5471–5481, 2004     

Conductive poly(butadiene-co-acrylonitrile)-polyaniline dodecylbenzenesulfonate [NBR-PAni.DBSA] blends prepared in solution

Blends of poly(butadiene-co-acrylonitrile) elastomer [NBR] and polyaniline dodecylbenzenesulfonate [PAni.DBSA], with electrical conductivities up to 10⁻² S cm⁻¹, have been prepared by solution mixing and casting. Miscibility was maximised for NBR with high acrylonitrile (ACN) content, as predicted on the basis of simple solubility parameter calculations. Blends prepared using NBR with 48 wt% ACN had the lowest electrical conductivity percolation thresholds, and were much more conductive than previous thermally mixed blends. Optical and electron micrographs of blends prepared from NBR 48 wt% ACN also showed the lowest levels of phase separation. The FT-IR spectra of NBR-PAni.DBSA blends resembled a superposition of the spectra of the pure materials, but with significant peak shifts due to changing intermolecular interactions between the polymers. Under DSC analysis, thermal events for blends prepared with NBR 48 wt% ACN also showed the largest temperature shifts relative to those for the pure polymers, supporting the other evidence for interaction between the two polymers.     

Synthesis and properties of processable conducting copolymers from N‐ethylaniline with aniline

Copolymers were synthesized through the chemically oxidative polymerization of N‐ethylaniline (EA) and aniline (AN) in five acid aqueous media. The polymerization yield, intrinsic viscosity, molecular weight, solubility, solvatochromism, electrical conductivity, and mechanical properties of the copolymer films were systematically studied through changes in the comonomer ratio, polymerization temperature, oxidant, oxidant/monomer ratio, and acid medium. Open‐circuit‐potential and temperature measurements of the polymerization solutions showed that the polymerization rate depended on the EA content, and the polymerization was an exothermic reaction. The resultant copolymers were characterized in detail with IR, ultraviolet–visible, and ¹H NMR spectroscopy, gel permeation chromatography, wide‐angle X‐ray diffractometry, and scanning electron microscopy. The reactivity ratios of the monomer pair were calculated from the ¹H NMR spectra of the copolymers formed at a low conversion. The polymers exhibited good solubility and interesting solvatochromism in most of the solvents and variable conductivity with the EA/AN ratio and doping state. The conductivity of the HCl‐doped copolymers increased monotonically from 5.61 × 10^?7 to 2.55 × 10^?1 S/cm with decreasing EA content from 100 to 0 mol % and showed a percolation transition between EA concentrations of 20 and 30 mol %. The EA/AN copolymers also had excellent film formability and flexibility together with high mechanical and oxygen‐enriching properties. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 6109–6124, 2004     

Reactive melt blends of thermoplastic polyolefins,MAH‐g‐PP and nylon 6

Reactive melt blends of an ethylene‐propylene‐diene terpolymer (EPDM) based thermoplastic elastomer (TPE), maleic anhydride grafted polypropylene (MAH‐g‐PP), and nylon 6 were prepared in a single screw extruder and evaluated in terms of morphological, rheological, thermal, dynamic mechanical, and mechanical properties of the blends. It was found that MAH‐g‐PP‐co‐nylon 6 copolymers were in situ formed and acted as effective compatibilizers for polypropylene (PP) and nylon 6. Phase separation of PP and EPDM in TPE increased with the addition and increasing amount of MAH‐g‐PP and nylon 6, leading to decreased glass transition temperature (T_g) of TPE and increased crystalline melting temperature (T_m) of PP. Copyright © 2004 John Wiley & Sons, Ltd.     

Electrical conductivity and polarization processes in nanocomposites based on isotactic polypropylene and modified synthetic clay

The direct‐current and alternating‐current electrical behavior of nanocomposites, formed by isotactic polypropylene partially modified with maleic anhydride and filled with different amounts of modified synthetic clay, has been studied; moreover, the conduction mechanisms and the relaxation processes that take place in the materials have been investigated. The nanocomposites containing small clay contents exhibit direct‐current insulating properties comparable to or even higher than those observed in the polymeric matrix. However, as the synthetic clay content increases, the ionic contribution to conductivity becomes considerable. The nanocomposites also show a slightly higher permittivity and loss factor than the host material because of the appearance of a thermally activated relaxation process in the frequency range of 10^?2 to 10² Hz at the investigated temperatures. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 705–713, 2007     

On the structure and electrical conductivity of polyaniline/polystyrene blends prepared by an aqueous‐dispersion blending method

This article describes electrically conductive polymer blends containing polyaniline‐dodecyl benzene sulfonic acid (PANI‐DBSA) dispersed in a polystyrene (PS) matrix or in crosslinked polystyrene (XPS). Melt blending of previously mixed, coagulated, and dried aqueous dispersions of PANI‐DBSA and PS latices lead to high conductivities at extremely low PANI‐DBSA concentrations (∼0.5 wt % PANI‐DBSA). In these blends, the very small size of the PANI‐DBSA particles and the surface properties (with surfactants used) of both the PANI and polymer particles play a major role in the PANI‐DBSA particle structuring process. The PANI‐DBSA behavior is characteristic of a unique colloidal polymeric filler with an extremely high surface area and a strong interaction with the matrix, evidenced by a significantly higher glass‐transition temperature of the matrix. The effect of the shear level on the conductivity and morphology of the PS/PANI‐DBSA blends was studied by the production of capillary rheometer filaments at various shear rates. An outstanding result was found for XPS/PANI‐DBSA blends prepared by the blending of aqueous XPS and PANI‐DBSA dispersions. Some of these blends were insulating at low shear levels; however, above a certain shear level, smooth surface filaments were generated, with dramatically increased and stable conductivities. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 611–621, 2001