Co-continuous phase structure formed in melt processing inducing shear bands to prevent crack propagation: Significant improvement in impact toughness of PMMA

High toughened polymeric materials have a wide application in many fields. Poly(methyl methacrylate) (PMMA) is a typical brittle polymer and it has been difficult to prepare high toughened PMMA material for a long time. To work on this issue, co-continuous phase structure was devised in PMMA/chlorinated polyethylene (CPE) blends through controlling the interfacial tension and viscosity in this work, resulting in the pronounced enhancement of impact toughness. The notched impact strength of co-continuous blends with 40 wt% CPE was up to 28.5 kJ/m², increased by 26 times compared with pure PMMA. Selective extraction experiments, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) showed that the CPE network was thin and weak when CPE addition was low, but became dense and strong once the content was more than 20 wt%. Two toughening mechanisms, i.e. cavitation and shear yielding, were put forward based on the micrographs of impact-fractured surfaces and double-notch four-point-bending test. This work may broaden the application prospects of PMMA and provide a new strategy to prepare high toughened polymeric materials through fabricating co-continuous in polymer blends.