Effect of fumed silica nanoparticles on the morphology and rheology of immiscible polymer blends

We examined the effect of interfacially active particles on the morphology and rheology of droplet/matrix blends of two immiscible homopolymers. Experiments were conducted on polybutadiene/polydimethylsiloxane (10/90) blend and the inverse system. The effects of fumed silica nanoparticles, at low particle loadings (0.1–2.0 wt%), were examined by direct flow visualization and by rheology. Fumed silica nanoparticles were found to significantly affect the morphology of polymer blends, inducing droplet cluster structure and decreasing the droplet size, regardless of which phase wets the particles preferentially. This is surprising in light of much past research that shows that particles are capable of bridging and thus induce droplet cluster structure in droplet/matrix systems only when they are preferentially wetted by the continuous phase. Therefore, there should exist other possible mechanisms responsible for these droplet cluster structures except for the bridging mechanism. We proposed a particle-flocculating mechanism based on the fact that fumed silica particles readily flocculate due to their high aspect ratio, fractal-like shape, or interparticle attractions. Optical microscopy also reveals that the clustering structure becomes more extensive, and the droplet sizes in the clusters become smaller when the particle loading is increased. Rheologically, the chief effect of particles is to change the flow behavior from a liquid-like rheology to gel-like behavior. This gel-like behavior can be attributed to droplet clustering. Moreover, it should be emphasized that such gel-like behavior can be seen in the blends regardless of which phase wets the particles preferentially, suggesting that, once again, bridging is not the only cause of droplet clustering.