This review examines some recent developments in the field of reactive compatibilization of polymer blends by melt processing in extruders and intensive batch mixers. Three routes to reactive compatibilization are considered, namely, the use of suitably functionalized blend constituents, the incorporation of polymeric compatibilizers, and the addition of low molecular weight compounds. Representative systems from the recent patent and open literature are classified according to method and assumed mechanism of compatibilization, and the types of chemical reactions involved. A variety of polymer blends are discussed, including impact modified thermoplastics, polymer modified engineering thermoplastics, dynamically vulcanized thermoplastic elastomers, and co‐crosslinked rubber/rubber blends. Examples of potential opportunities in reactive compatibilization are also presented.

The rapid growth in the use of multiphase polymer systems (blends and composites) is undoubtedly related to the availability of methods of controlling the physical and chemical interactions at the interface. Compounds acting as interfacial agents are commonly known as “compatibilizers” in blends, or “coupling agents” in composites; their function is to promote adhesion and enhance overall properties. This paper is a review of recent advances in the use of these compounds in immiscible polymer blends and thermoplastic composites. Polymeric compatibilizers are classified according to their method of addition (in situformation vs. separate addition) and reactivity. Reactive low molecular weight compounds are also listed and their various coupling mechanisms are discussed. It is demonstrated that common routes to enhanced adhesion exist for some types of blends and composites. For example, reactive graft copolymers and certain crosslinklng agents are equally effective as adhesion promoters in blends and composites containing a polyolefin phase.

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The reactivity and efficiency of five low molecular weight multifunctional anhydride and epoxy compounds as chemical modifiers of a bottle grade poly(ethylene terephthalate) (PET) resin were evaluated by reactive extrusion under controlled conditions. The two dianhydrides and the three epoxy compounds were used at concentrations based on stoichiometry derived from the measured carboxyl and hydroxyl end group contents of the base resin. Measures of melt viscosity, melt strength, intrinsic viscosity and carboxyl group content were used as criteria of the extent of the modification. Correlations of die pressure with extrudate swell during extrusion, and melt flow index (MFI) with melt strength by off‐line testing of the extrudates permitted the ranking of the modifiers according to their chain‐extending/branching efficiency. For some systems molecular weight increases (related to die pressure/MFI/intrinsic viscosity) accompanied by broadening of the molecular weight distribution (related to die swell/melt strength) were considered excessive. Extrusion foaming experiments with one particular dianhydride modifier that increased the intrinsic viscosity of the resin from 0.71 to 0.9 dl g−1 indicate that production of low‐density foams by a process involving one‐step reactive modification/gas injection foaming is feasible, at conditions not significantly different from those employed in the simple reactive modification of the PET resin. The rheological and structural parameters determined in this work may be used as criteria to specify PET foamable compositions in terms of types and concentrations of modifiers. Copyright © 2004 Society of Chemical Industry

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