Nanophase Separation in Immiscible Double Network Elastomers Induces Synergetic Strengthening, Toughening, and Fatigue Resistance

High modulus, toughness, and fatigue resistance are usually difficult to be obtained simultaneously in rubbery materials. Here, we report that by superimposing the nanophase separation structure in double network (DN) elastomers using immiscible polymers, the modulus, fracture energy, and energy release rate of fatigue threshold are enhanced all together by 13, 5, and 5 times, respectively. We reveal that the interplay between the DN structure and the nanophase separation structure brings two effects synergistically: (1) formation of nanoclusters overstresses and homogenizes the sacrificial network, thereby remarkably increasing the modulus and yielding stress and (2) the nanoclusters act as viscoelastic nanofillers dissipating energy and pinning the crack propagation, thereby significantly enhancing toughness and fatigue resistance. This work provides a facile approach to superimpose high-order structures in DN materials for excellent mechanical performance. The clarified synergetic effects should be universal for DN materials made of immiscible polymers. We believe that this work will facilitate more studies on elastomers and gels along this line.