The morphology build-up in toughened epoxy blends using reactive hyperbranc
hed dendritic polymers (HBP) and amine-cured epoxy resins has been investig
ated in the present work. By changing the processing conditions or the surf
ace chemistry of the modifier, very different morphologies can be obtained,
ranging from homogeneous blends to coarse two-phase systems. The morpholog
y characterised by electron and optical microscopy has been interpreted com
bining constitutive equations for phase separation and thermodynamic modell
ing of phase interactions. The latter model, based on the Flory-Huggins lat
tice theory, was modified in order to take into account the addition reacti
vity of the HBP modifiers. This approach proved successful and can be used
as a tool for final morphology prediction in any reactive blend formulation
.