Co-continuous phase structure formed in melt processing inducing shear bands to prevent crack propagation: Significant improvement in impact toughness of PMMA

High toughened polymeric materials have a wide application in many fields. Poly(methyl methacrylate) (PMMA) is a typical brittle polymer and it has been difficult to prepare high toughened PMMA material for a long time. To work on this issue, co-continuous phase structure was devised in PMMA/chlorinated polyethylene (CPE) blends through controlling the interfacial tension and viscosity in this work, resulting in the pronounced enhancement of impact toughness. The notched impact strength of co-continuous blends with 40 wt% CPE was up to 28.5 kJ/m2, increased by 26 times compared with pure PMMA. Selective extraction experiments, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) showed that the CPE network was thin and weak when CPE addition was low, but became dense and strong once the content was more than 20 wt%. Two toughening mechanisms, i.e. cavitation and shear yielding, were put forward based on the micrographs of impact-fractured surfaces and double-notch four-point-bending test. This work may broaden the application prospects of PMMA and provide a new strategy to prepare high toughened polymeric materials through fabricating co-continuous in polymer blends. [Display omitted] •Co-continuous phase structure was devised in PMMA/CPE blends.•The impact strength of PMMA/CPE blends was 26 times higher than that of pure PMMA.•Low interfacial tension and equal viscosity were main reason for phase formation.•Two toughening mechanisms, i.e. cavitation and shear yielding, were put forward.•This work provides a new strategy to prepare high toughed polymer materials.