Does conventional nucleation occur during phase separation in polymer blends?

The kinetics of liquid-liquid phase separation in off-critical polymer blends was studied with time-resolved small-angle neutron scattering. Our objective was to study the nature of the nuclei that formed during the initial stages of the phase transition. The blends were composed of model polyolefins-deuterium-labeled poly(methyl butylene) (PMB) and poly(ethyl butylene) (PEB)-with molecular weights of about 200 kg/mol. A direct examination of the initial clustering of molecules before macroscopic phase separation was possible because of the large size of the polymer chains and concomitant entanglement effects. We discovered that the scattering profiles obtained during nucleation merged at a well-defined critical scattering vector. We propose that this is the signature of the critical nucleus and that the size of the critical nucleus is inversely proportional to the magnitude of the critical scattering vector. The kinetic studies were preceded by a thorough characterization of the equilibrium thermodynamic properties of our PMB/PEB blends. The locations of the binodal and spinodal curves of our system are consistent with predictions based on the Flory-Huggins theory. This combination of thermodynamic and kinetic experiments enabled the quantification of the dependence of the size and structure of the critical nuclei on the quench depth. Our results do not agree with any of the previous theories on nucleation. Some aspects of our results are addressed in recent theoretical work by Wang in which the effects of fluctuations on the classical binodal and spinodal curves in polymer blends are incorporated. Both theory and experiment support the notion that the traditional stability limit (spinodal) should be replaced by a metastability limit. Although Wang's theory provides an explanation for some of our observations, many fundamental issues regarding nucleation in polymer blends remain unresolved. (C) 2004 Wiley Periodicals, Inc.