Effect of polycarbonate (PC) content on the mechanical properties, morphology and transesterification mechanism of PBT/PC immiscible blends

Abstract This study focuses on the experimental investigation of the mechanical properties of PBT/PC blends with varying compositions. The studied mechanical properties include tensile strength, elongation, tensile modulus, impact strength, and Shore hardness of PBT/PC blends with different PC contents. PBT, characterized by its semi‐crystalline and tough nature, contrasts with PC, known for its impact resistance and hardness. Achieving an optimal blend composition proves to be crucial for attaining the best combination of these properties. The tensile strength of the PBT/PC 30/70 blend increased by approximately 24%, with Shore hardness also experienced a 12% enhancement compared to pure PBT. This improvement is attributed to the presence of PC segments in the blend structure. Conversely, an increase in PC content led to the elongation and impact strength of the blends peaking in the PBT/PC 70/30 blend. Notably, the impact strength of the PBT/PC blend with 30% PC increased by about three times compared to PBT and 18% more than pure PC. Scanning Electron Microscopy (SEM) analysis revealed that PBT and PC segments disperse at lower PC content, while at higher content, phase separation becomes prominent. Fourier Transform Infrared Spectroscopy (FTIR) analysis indicates direct transesterification between PBT and PC, resulting in the formation of a long‐chain blend structure with random copolymer blocks. The transesterification mechanism is also supported by Differential Scanning Calorimetry (DSC) results, wherein a reduction in the crystallization temperature ( T c ) and an increase in the glass transition temperature ( T g ) is observed. The study concludes that the volume of these segments and their bonding play a decisive role in determining the mechanical properties. The bonding mechanism elucidated through FTIR and SEM provides valuable insights into the fabrication and property engineering of PBT/PC blends.