Styrene-butadiene-styrene copolymer compatibilized carbon black/polypropylene/polystyrene composites with tunable morphology, electrical conduction and rheological stabilities.

We report a facile kinetic strategy in combination with styrene-butadiene-styrene (SBS) copolymer compatibilizers for preparing carbon black (CB) filled immiscible polypropylene (PP)/polystyrene (PS) (1/1) blends with finely tuned morphologies and show the important role of location and migration of CB nanoparticles in determining the electrical conductivity and rheological behaviour of the composites. A novel method of mixing a SBS/CB (5/3) masterbatch with the polymers allowed producing composites with CB aggregates dispersed partially in the unfavorable PP phase and partially in the PP side of the interface to exhibit diverse phase connectivity and electrical conductivity depending on the compounding sequences. A cocontinuous morphology with CB enrichment along the interface was formed in the composite prepared by mixing the SBS/CB masterbatch with the premixed PP/PS blend, giving rise to a highest electrical conductivity and dynamic moduli at low frequencies. On the other hand, mixing the masterbatch with one and then with another polymer yielded droplet (PS)-in-matrix (filled PP) composites. The composites underwent phase coalescence and CB redistribution accompanied by marked dynamic electrical conduction and modulus percolations as a function of time during thermal annealing at 180 °C. The composites with the initial droplet-in-matrix morphology progressed anomalously into the cocontinuous morphology, reflecting a common mechanism being fairly nonspecific for understanding the processing of filled multicomponent composites with tailored performances of general concern.