Toughening of polycarbonate: Effect of particle size and rubber phase contents of the core-shell impact modifier

The toughening behavior of polycarbonate modified with core-shell type particles was investigated. The alloys were found to exhibit maximum impact strength upon addition of a modifier with a poly(butyl acrylate) rubbery core of 0.25 mum diameter. The incorporation of particles with diameter greater than 0.25 mum resulted in decreased impact strength. The influence of rubber phase contents on toughness was also studied. It was observed that the alloys exhibited maximum impact strength upon addition of 4 wt% rubber phase. Further increase in the rubber phase content resulted in reduced impact strength. Fractography of the samples showed that, below 4 wt% rubber phase content, the fracture occurs mainly by internal crazing and, from 4 wt% onward, only by shear deformation. When the effect of dual particle size distribution was analyzed, it was found that there was only a moderate increase in toughness compared with alloys containing monosized particles. (C) 2004 Wiley Periodicals, Inc.