Intractable high‐Tg thermoplastics processed with epoxy resin: Interfacial adhesion and mechanical properties of the cured blends

The intractable, high‐temperature‐resistant thermoplastics (TPs) polyphenylenether (PPE) and polyetherimide (PEI) were processed by dissolution into epoxy–amine precursors and a subsequent reaction of the precursors. Because the TP concentration was higher than the critical concentration, the phase separation produced a dispersion of crosslinked thermoset (TS) particles into a TP matrix. The morphology of the blends was examined with transmission electron microscopy and dynamic mechanical thermal spectroscopy, which showed completion of the phase separation. The interfacial adhesion at the TP‐matrix/TS‐particle interface was estimated on TP/TS bilayers to be 10 J/m² in PEI blends, whereas it was 70 J/m² in PPE blends, where there is strong evidence for in situ grafting between PPE phenolic chain ends and glycidyl functions of the reactive TS. Yielding in the compressive mode occurred at an intermediate yield stress between the components' values, and the anelastic deformation was separated from the plastic deformation. Fractures in the tensile mode occurred through debonding at the matrix/particle interfaces and coalescence of these defects, which led to microcrack formation and brittle failure. Mode I fracture toughness was, therefore, higher for PPE blends than for PEI blends, a result of the higher interfacial adhesion. However, a decrease from pure TP was observed. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 363–373, 2001