AbstractGlassy polymers undergo relatively rapid physical aging just below their glass transition temperatures that can lead to embrittlement of normally tough materials like polycarbonate (PC). One approach for solving the embrittlement problem is to incorporate an impact modifier that can cause toughening when the matrix loses its inherent ductility due to physical aging. The effects of thermal aging below the glass transition temperature of polycarbonate on selected properties of blends of PC with various core‐shell impact modifiers have been studied. Observed changes in mechanical properties are related to rubber content, free volume, fracture morphology, discoloration, enthalpy relaxation, glass transition temperature, intrinsic viscosity, and dynamic mechanical behavior. Blend mechanical properties are affected by chemical changes in the impact modifier that occur simultaneous with the physical aging of the PC matrix. The degradation mechanisms involved reduce the effectiveness of the modifier for toughening and also lead to a loss of molecular weight of the PC matrix. Blends containing 10 methacrylated butadiene‐styrene (MBS) core‐shell impact modifiers give the maximum extension of time to embrittlement at 135°C in air. More thermally stable modifiers are required for further extending the ductile mode of failure for physically aged PC
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