Unlocking Interfacial Synergies: in Situ Multi-Step Reaction-Induced Control for High-Performance and Functional Polybutylene Terephthalate/polyolefin Blends from Recycled Sources

This investigation employed free radical melt grafting technology for the synthesis of (POE/R-LLDPE)-g-(GMA-co-St) graft copolymers. Subsequently, this graft copolymer was applied as a modifier for poly (butylene terephthalate) (PBT) resin. The effects of varying recycled linear low-density polyethylene (R-LLDPE) contents in the graft on the rheological behavior, thermal properties, mechanical properties, and toughening mechanism of PBT/(POE/R-LLDPE)-g-(GMA-co-St) blends were exhaustively explored. The findings revealed that glycidyl methacrylate (GMA) and styrene (St) were effectively grafted onto the poly (ethylene-octene) (POE) and R-LLDPE molecular chains. This process enabled the epoxy groups in the GMA of the graft to react with the terminal groups of the PBT resin, thereby enhancing its compatibility with PBT. The use of R-LLDPE-g-(GMA-co-St) or POE-g-(GMA-co-St) as singular modifiers did not produce optimal modification results. Conversely, the most effective modification of the PBT resin was observed when both were combined, indicating a pronounced synergistic modification effect. The optimal overall performance of the blend was noted when the R-LLDPE content in the graft copolymer was 50 wt%. This method significantly enhanced the toughness of the blend while preserving excellent thermal stability and mechanical strength, concurrently reducing the product cost. At this point, a high concentration of voids was observed in the stress-whitening area of the impact specimens. The PBT matrix displayed conspicuous shear yielding with a notably rough impact fracture surface, manifesting highly significant tough fracture characteristics.