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This paper reconstructs the principle of rubber incorporation in high impact poly(propylene) (hiPP) particles. The detailed information about the pores and rubber distribution inside and on the surface of hiPP particles is obtained by micro-computed tomography and atomic force microscopy. The strong effect of homopolymer origin on hiPP particle morphology and rubber distribution is demonstrated. To obtain the most homogeneous rubber distribution, the low homopolymer porosity is required. The initial particle porosity has a negligible effect on the thickness of the rubber layer on the particle surface at the medium rubber content. The rubber forms not only along the iPP primary particles and directly or close to the pores but also on or close to the particle surface rather than it flows there. The evidence for these claims is based on the systematic investigation in dependence on EPR content, homopolymer particle porosity (prepared by different catalysts) and antistatic agent deactivating catalyst close to particle surface. [ABSTRACT FROM AUTHOR]

Highlights: [•] The 3D distribution of pores and EPR zones was visualized by microCT. [•] AFM phase imaging shows fine EPR network spread over entire hiPP particles. [•] Simultaneous AFM phase and height imaging determines EPR covering particle surface. [•] EPR does not cover whole particle surface at medium-degree of coverage. [•] The EPR squeezed out of the microtomed surface causes artifacts on AFM images. [Copyright &y& Elsevier]