Stability of the co‐continuous morphology during melt mixing for poly(ε‐caprolactone)/polystyrene blends

Over the last 10 years, research into co‐continuous polymer blends has been intense. Despite these efforts, there are very few detailed studies on the stability of this complex morphology. In this work, blends of poly(ε‐caprolactone) and polystyrene were melt‐mixed in an internal mixer for time intervals of 0.5–120 min at set temperatures of 140 and 170 °C, and the effect of the mixing time on the co‐continuous morphology was studied. This blend system was chosen because each component could be selectively dissolved and this allowed for a complete study of the co‐continuous region. The phase continuity was measured with a solvent‐extraction gravimetric technique, and the concentration range for co‐continuity was determined. The phase size and phase size distribution were obtained with the mercury intrusion porosimetry technique. The results indicate that the co‐continuous morphology forms very early in the mixing process and achieves a stable morphology within the first 5 min of mixing for virtually all the co‐continuous compositions. For all cases studied, the co‐continuous morphology remains unchanged over mixing times as long as 1–2 h. These results support the notion of a stable steady‐state formation of co‐continuous morphologies during melt mixing similar to that observed for matrix/dispersed phase type blends. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 864–872, 2007