The effects of pressure and shear rate on the miscibility of binary blends comprising bisphenol-A polycarbonate (PC) and low molecular weight poly(methyl methacrylate) (PMMA) were investigated using a capillary rheometer. Both pressure and shear rate affected the miscibility. The examination of an extruded strand of the blend provided information about the cause of the phase change. Under high pressure, pressure-induced demixing occurred at temperatures below the lower critical solution temperature (LCST) of the blend. Consequently, the extruded strand became opaque throughout. During shear-induced mixing/demixing, a part of the strand became opaque because of the distribution of the shear rate in the strand. For example, during shear-induced demixing, only the exterior of the strand, i.e., the high shear rate region, became opaque. Above the LCST, shear-induced mixing occurred, and only the center region of the strand became opaque.

Miscible blends composed of bisphenol-A polycarbonate (PC) and poly(methyl methacrylate) (PMMA), in which one of them has low molecular weight, were employed to study the surface segregation behavior during flow. The blend samples showed typical rheological behaviors, such as simple polymer melts without a long-time relaxation mechanism ascribed to phase separation, demonstrating that they were miscible. After injection molding, the amounts of a low molecular weight component on the blend surface were found to be larger than the actual blend ratio. Because the injection-molded products were transparent despite a huge difference in refractive indices between PC and PMMA, they showed no phase separation. This result demonstrated that surface segregation of a low molecular weight component occurred under flow field, which expands the material design such as tough plastics with good scratch resistance and optical fibers with tapered refractive index.

The rheological behavior under pressure‐driven shear flow was studied using binary blends with a sea‐island structure. The addition of a low‐viscosity dispersion having a high interfacial tension with the continuous phase greatly reduces the shear viscosity, for example, the addition of atactic polystyrene (PS) with a low viscosity to isotactic polypropylene (PP) and the addition of PP with a low viscosity to PS. The interfacial slippage occurs because of the poor adhesive strength with the enlarged interfacial area and is responsible for the viscosity decrease. When the dispersion has a similar viscosity to the continuous phase, the viscosity decrease is barely detected. This is because the deformation of dispersed droplets is restricted, which creates a small interfacial area. The interfacial tension between the continuous and dispersed phases plays a crucial role on the shear viscosity. In the case of PP, the addition of linear low‐density polyethylene with a relatively low interfacial tension to PP has almost no impact on the shear viscosity. This is despite the polyethylene having a low viscosity.