Commercial Polymer Blends

In this chapter, an overview of the commercially important blends is presented with a particular emphasis on the rationale for their commercial development, the compatibilization principles, their key mechanical properties and their current applications a

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COMMERCIAL POLYMER BLENDS

M. K. AKKAPEDDI

Honeywell Inc., EAS R & T, Morristown, USA

15.1

Abstract

In this chapter, an overview of the commercially important blends is presented with a particular emphasis on the rationale for their commercial development, the compatibilization principles, their key mechanical properties and their current applications and markets. To facilitate the discussion, the commercial polymer blends have been classified into twelve major groups depending on the type of the resin family they are based on, viz. (i) polyolefin, (ii) styrenic, (iii) vinyl, (iv) acrylic, (v) elastomeric, (vi) polyamide, (vii) polycarbonate, (viii) poly(oxymethylene), (ix) polyphenyleneether, (x) thermoplastic polyester, (xi) specialty polymers, and (xii) thermoset blends. Within each major category, the individual polymer blends of industrial significance have been described with relevant data. Since the discussion is limited only to those blends that are actually produced and used on a commercial scale, the relevant cost and performance factors that contribute to the commercial viability and success of various types of blends have been outlined. In comparing the different blends, the specific advantages of each type, as well as any potential overlap in performance with other type of blends have also been discussed. The fundamental advantage of polymer blends viz. their ability to combine cost-effectively the unique features of individual resins, is particularly illustrated in the discussion of crystalline/amorphous polymer blends, such as the polyamide and the polyester blends. Key to the success of many commercial blends, however, is in the selection of intrinsically complementing systems or in the development of effective compatibilization method. The use of reactive compatibilization techniques in commercial polymer blends has also been illustrated under the appropriate sections such as the polyamide blends. In many commercial blends, rubber toughening plays an important and integral part of the blend design. Combining high impact strength with other useful properties such as heat and solvent resistance can significantly enhance the commercial value of a blend. Hence, the nature of the impact modifiers used and the role of morphology on properties have been discussed under the appropriate cases of commercial blends. The chapter concludes with an outline of the potential trends in the commercial polymer development. L.A. Utracki (Ed.), Polymer Blends Handbook, 1023-1115. © 2003 Kluwer Academic Publishers. Printed in the Netherlands.

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15.2

M. K. Akkapeddi

Introduction

Polymer blends have gained significant commercial growth in the last two decades outpacing the growth rate of existing polymers by at least 2 to 5%. The current worldwide market volume for polymer blends and alloys is estimated to be more than 700,000 metric ton/y, with an average growth rate of 6 to 7%. Although this pace of growth slightly slackened during the ‘90’s, the demand for polymer blends is expected to be maintained due to the po