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<p>Rubber-toughened thermoplastic materials have become ubiquitous in modern society owing to their lightweight nature and desirable combination of advantageous performances. Despite the ever-increasing demand, the development of polymer alloys that are lightweight, high-strength, and high-toughness remains an ongoing challenge. Inspired by the unique “salami” microstructure from commercial acrylonitrile butadiene styrene copolymer (ABS) and high-impact polystyrene (HIPS), a facile approach was developed to overcome the trade-off between enhancing the toughness and rigidity of fully polymer-based alloys by virtue of elastomeric salami particles. This strategy entails pre-grafting rigid poly(lactic acid) (PLLA) chains with glycidyl methacrylate-grafted octene ethylene copolymer (POE-<i>g</i>-GMA) using complementary reactive groups. It can be envisaged that the PLLA grafts featuring strong incompatibility with polypropylene (PP) remain fixed in elastomer phase upon the subsequent melt compounding, facilitating the <i>in situ</i> formation of “hard core (PLLA)-soft shell (polyolefin elastomer, POE)” particles in polypropylene (PP) matrix. The all-polymer alloys containing elastomeric salami particles demonstrated unprecedented performance combinations, including upper notched impact strengths (56.8 kJ/m<sup>2</sup>), even higher tensile strength (36.8 MPa), and Young’s modulus (0.93 GPa) than that of the PP matrix. Furthermore, these materials are lightweight without the incorporation of reinforcing nano-fillers, which is competitive with industrial engineering plastics. It is highly anticipated that this universal and highly efficient protocol will be appropriate for arbitrary rubber toughened/reinforced systems, offering a paradigm in the design of advanced all-polymer alloys.</p>

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Overcoming the Trade-off between Toughness and Stiffness of Fully Polymer-based Alloys by Elastomeric Salami Particles through Reactive Blending

  • 期刊论文

  • 发表日期：

    2026年2月6日

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  • Yan Xia,
  • Ming-Hui Sang,
  • Xiao Wang,
  • Ning He,
  • Heng-Ti Wang,
  • Yong-Jin Li

摘要

Rubber-toughened thermoplastic materials have become ubiquitous in modern society owing to their lightweight nature and desirable combination of advantageous performances. Despite the ever-increasing demand, the development of polymer alloys that are lightweight, high-strength, and high-toughness remains an ongoing challenge. Inspired by the unique “salami” microstructure from commercial acrylonitrile butadiene styrene copolymer (ABS) and high-impact polystyrene (HIPS), a facile approach was developed to overcome the trade-off between enhancing the toughness and rigidity of fully polymer-based alloys by virtue of elastomeric salami particles. This strategy entails pre-grafting rigid poly(lactic acid) (PLLA) chains with glycidyl methacrylate-grafted octene ethylene copolymer (POE-g-GMA) using complementary reactive groups. It can be envisaged that the PLLA grafts featuring strong incompatibility with polypropylene (PP) remain fixed in elastomer phase upon the subsequent melt compounding, facilitating the in situ formation of “hard core (PLLA)-soft shell (polyolefin elastomer, POE)” particles in polypropylene (PP) matrix. The all-polymer alloys containing elastomeric salami particles demonstrated unprecedented performance combinations, including upper notched impact strengths (56.8 kJ/m2), even higher tensile strength (36.8 MPa), and Young’s modulus (0.93 GPa) than that of the PP matrix. Furthermore, these materials are lightweight without the incorporation of reinforcing nano-fillers, which is competitive with industrial engineering plastics. It is highly anticipated that this universal and highly efficient protocol will be appropriate for arbitrary rubber toughened/reinforced systems, offering a paradigm in the design of advanced all-polymer alloys.