Controlling the Mixing Sequence of the Reactive Compatibilizer SAN-g-Epoxy in PBT/ABS Blends: Enhancing Mechanical and Thermomechanical Performance Through Interfacial Engineering

Polymer blends constitute a strategy for tailoring the properties of commercial polymers, leading to the development of materials designed for specific applications. In this work, the effect of the mixing sequence of the reactive compatibilizer styrene–acrylonitrile functionalized with epoxy groups (SAN-g-Epoxy) on the performance of poly(butylene terephthalate) (PBT)/acrylonitrile–butadiene–styrene (ABS) blends was investigated. PBT/ABS blends (60/40 wt%) were prepared by reactive extrusion in a twin-screw extruder followed by injection molding, incorporating five parts per hundred resin (phr) of SAN-g-Epoxy through different mixing sequences, aiming to understand how the processing order influences interfacial reactions, morphology, and the final properties of the material. The results indicated that SAN-g-Epoxy promotes reactive compatibilization between PBT and ABS, as evidenced by a significant increase in torque and complex viscosity, as well as by an increase in the intensity of the carbonyl band in the Fourier transform infrared spectroscopy (FTIR) spectra. By scanning electron microscopy (SEM), the presence of the compatibilizer resulted in a pronounced morphological refinement of the dispersed ABS phase, reducing the average particle size from approximately 4.34 µm to about 0.47–0.54 µm. Among the processing strategies, the route (PBT/SAN-g-Epoxy) + ABS exhibited the best mechanical performance under impact, reaching 206.7 J/m. However, the simultaneous mixing sequence PBT/ABS/SAN-g-Epoxy showed the best balance of properties, with gains of 203% in impact strength, 8.8% in elastic modulus, and 40.1% in heat deflection temperature (HDT) compared to neat PBT. The results indicate that PBT can be improved and tailored for engineering applications.