Rubber toughening and damage competition theory. In material selection it is important to look at the interaction between the matrix and the secondary phase. For example, crosslinking within the rubber phase will promote high strength fibril formation that will toughen the rubber, preventing particle fracture. Carboxyl-terminated butadiene-acrylotnitrile (CTBN) is often used to toughen epoxies, but using CTBN alone increases the toughness at the cost of stiffness and heat resistance. Amine-terminated butadiene acrylonitrile (ATBN) is also used. Using ultra-fine full-vulcanized powdered rubber (UFPR) researchers have been able to improve all three, toughness, stiffness, and heat resistance simultaneously, resetting the stage for rubber toughening
Rubber toughening materials where crazing and yielding are comparable, a bimodal distribution of particle size may be useful for toughening. At fixed rubber concentrations, one can find that an optimal particle size is a function of the entanglement density of the polymer matrix. The neat polymer entanglement densities of PS, SAN, and PMMA are 0.056, 0.093, and 0.127 respectively. As entanglement density increases, the optimum particle size decreases linearly, ranging between 0.1 and 3 micrometers. The effect of particle size on toughening is dependent on the type of test performed. This can be explained because for different test conditions, the failure mechanism