Improvement in Processability for Injection Molding of Bisphenol-A Polycarbonate by Addition of Low-Density Polyethylene.

The rheological properties and processability at injection molding were studied for bisphenol-A polycarbonate (PC) that was modified by low-density polyethylene (LDPE) having a low shear viscosity. The LDPE addition significantly decreased the steady-state shear viscosity, especially in the high shear rate region. The decrease did not originate from slippage on the die wall but due to interfacial slippage between the PC and dispersed LDPE droplets that deformed to the flow direction to a great extent. As a result of the viscosity decrease, injection pressure largely decreased from 150 to 110 MPa with the addition only 5 wt.% of LDPE. The enhanced flowability also reduced the warpage of the molded product significantly, demonstrating that the processability at injection molding was improved by the addition of LDPE.

Segregation Behavior of Miscible PC/PMMA Blends during Injection Molding.

Miscible blends composed of bisphenol-A polycarbonate (PC) and poly(methyl methacrylate) (PMMA), in which one of them has low molecular weight, were employed to study the surface segregation behavior during flow. The blend samples showed typical rheological behaviors, such as simple polymer melts without a long-time relaxation mechanism ascribed to phase separation, demonstrating that they were miscible. After injection molding, the amounts of a low molecular weight component on the blend surface were found to be larger than the actual blend ratio. Because the injection-molded products were transparent despite a huge difference in refractive indices between PC and PMMA, they showed no phase separation. This result demonstrated that surface segregation of a low molecular weight component occurred under flow field, which expands the material design such as tough plastics with good scratch resistance and optical fibers with tapered refractive index.

Complicated Structure Change during Capillary Extrusion of Binary Blends of Polycarbonate and Poly(methyl methacrylate).

The effects of pressure and shear rate on the miscibility of binary blends comprising bisphenol-A polycarbonate (PC) and low molecular weight poly(methyl methacrylate) (PMMA) were investigated using a capillary rheometer. Both pressure and shear rate affected the miscibility. The examination of an extruded strand of the blend provided information about the cause of the phase change. Under high pressure, pressure-induced demixing occurred at temperatures below the lower critical solution temperature (LCST) of the blend. Consequently, the extruded strand became opaque throughout. During shear-induced mixing/demixing, a part of the strand became opaque because of the distribution of the shear rate in the strand. For example, during shear-induced demixing, only the exterior of the strand, i.e., the high shear rate region, became opaque. Above the LCST, shear-induced mixing occurred, and only the center region of the strand became opaque.