In situ polymerized PS/EPDM blends were prepared by dissolving poly(ethylene-co-propylene-co-2-ethylidene-5-norbornene) (EPDM) in styrene monomer, followed by bulk polymerization at 60 degrees C and 80 degrees C. EPDM has excellent resistance to such factors as weather, ozone and oxidation, attributed to its non-conjugated diene component, and it could be a good alternative for substituting polybutadiene-based rubbers in PS toughening. The in situ polymerized blends were characterized by dynamic mechanical analysis, thermogravimetric analysis, gel permeation chromatography, and tensile and Izod impact resistance tests. The PS/EPDM blends are immiscible and present two phases, a dispersed elastomeric phase (EPDM) in a rigid PS matrix whose phase behavior is strongly affected by the polymerization temperature. Mechanical properties of the blends are influenced by the increase in the average size of EPDM domains with the increase in the polymerization temperature and EPDM content. The blends polymerized at 60 degrees C containing 5 wt% of EPDM presents an increase in the impact resistance of 80% and containing 17 wt% of EPDM presents an increase in the strain at break of 170% in comparison with the value of PS. The blend polymerized at 80 degrees C containing 17 wt% of EPDM presents an increase in the strain at break of 480% and in impact resistance of 140% in comparison with the value of PS. (c) 2006 Elsevier Ltd. All rights reserved.421026322645