Relationship between the Processing, Structure, and Properties of Microfibrillar Composites

Highly Tough Yet Stiff, Transparent, and Recyclable PMMA Nanocomposites Incorporating TPU Nanofibril Networks with High Thermal Stability and Strong Interfacial Adhesion

In this paper, we develop high aspect ratio nanofibrils from a polycaprolactone-based thermoplastic polyurethane (TPU) and evaluate their performance as a toughening agent. Poly(methyl methacrylate) (PMMA) was chosen as the matrix material because of its inherent brittleness and low resistance to sudden shocks and impact. We show that the addition of as little as 3 wt % of TPU nanofibrils with an average diameter of ∼98 nm and very high aspect ratio can significantly improve both the tensile toughness (∼212%) and impact strength (∼40%) of the chosen matrix (i.e., PMMA) without compromising its original strength, stiffness, and transparency. We compare the performance of TPU nanofibrils with TPU spherical particles─the form TPU typically manifests into when melt-mixed with an immiscible polymer. Our findings highlight that the structure of TPU plays a crucial role in determining the critical concentration of TPU needed for the brittle-ductile transition of the matrix. We also provide new and valuable insights into the unique interfacial interaction (i.e., formation of fibrillar bridges) observed between the PMMA matrix and TPU. We also show that the inclusion of 3 wt % of TPU nanofibrils can notably enhance resistance to creep deformation, even at temperatures close to the glass transition temperature of the matrix. Finally, we evaluate recyclability and demonstrate that the composite containing 3 wt % of TPU nanofibrils can be mechanically recycled without losing any properties. The proposed TPU nanofibrils can withstand repeated reprocessing at temperatures up to 190 °C due to their very high melting point and thermal stability. This presents the opportunity for them to be utilized not just with amorphous PMMA, but also with a range of other materials that can be processed at or below this temperature to remarkably improve their toughness without sacrificing strength and stiffness.

Biodegradable nanofibrillated microcellular PBS/PLA foams for selective oil absorption

To address the challenges posed by spilled oil and oily wastewater, the development of clean oil-adsorption materials is crucial. However, traditional oil-adsorption materials suffer from the issue of secondary pollution. Herein, fully biodegradable nanofibrillated poly(butylene succinate)/poly(lactic acid) (PBS/PLA) foams with outstanding selective oil-adsorption performance were successfully fabricated via an eco-friendly supercritical CO2 foaming technology. The PBS/PLA composites, featuring nanofibrils with a diameter of approximately 100 nm, were prepared through a hot-stretching method subsequent to extrusion. Substantial improvements were observed in the crystallization rate and rheological properties of the fibrillated PBS/PLA composites. Furthermore, PLA nanofibrils enhanced foamability of the composite, achieving an impressive expansion ratio of up to 38.0, resulting in an outstanding oil-absorption performance (19.2-50.4 g/g) of the F-1 %-95 foam. Additionally, 20 adsorption-desorption cycles illustrated the prepared F-1 %-95 foam displayed recyclable oil-absorption characteristics. This work provides an eco-friendly strategy for preparing fully biodegradable foams intended for application as oil-adsorption materials.

Spatial Heterogeneity Directs Energy Dissipation in Condylar Fibrocartilage

Condylar fibrocartilage with structural and compositional heterogeneity can efficiently orchestrate load-bearing and energy dissipation, making the temporomandibular joint (TMJ) survive high occlusion loads for a prolonged lifetime. How the thin condylar fibrocartilage can achieve efficient energy dissipation to cushion enormous stresses remains an open question in biology and tissue engineering. Here, three distinct zones in the condylar fibrocartilage are identified by analyzing the components and structure from the macro-and microscale to the nanoscale. Specific proteins are highly expressed in each zone related to its mechanics. The heterogeneity of condylar fibrocartilage can direct energy dissipation through the nano-micron-macro gradient spatial scale, by atomic force microscope (AFM), nanoindentation, dynamic mechanical analyzer assay (DMA), and the corresponding energy dissipation mechanisms are exclusive for each distinct zone. This study reveals the significance of the heterogeneity of condylar fibrocartilage in mechanical behavior and provides new insights into the research methods for cartilage biomechanics and the design of energy-dissipative materials.

Robust, Fully Biodegradable Films of Polyesters Realized by In Situ Formation of an Interconnected Multi-Nanolayer Structure under Extensional Flow

Multilayer structures are not only applied to manipulate properties of synthetic polymer materials such as rainbow films and barrier films but also widely discovered in natural materials like nacre. In this work, in situ formation of an interconnected multi-nanolayer (IMN) structure in poly(butylene adipate-co-terephthalate) (PBAT)/poly(butylene succinate) (PBS) cocontinuous blends is designed by an extensional flow field during a "casting-thermal stretching" process, combining the properties of two components to a large extent. Hierarchical structures including phase morphology, crystal structure, and lamellar crystals in IMN films have been revealed, which clearly identifies the crucial role of extensional flow. The oriented PBAT phase in the IMN structure can be beneficial to the epitaxial growth of PBS crystals onto the PBAT nanolayers, thus improving interfacial adhesions. Furthermore, intense extensional stress can also promote crystallinity and thicken the lamellar structure. Given such distinct features in the fully biodegradable films, a simultaneous enhancement in tear strength, tensile strength, and puncture resistance has been achieved. To the best of our knowledge, the tear strength of IMN films about 285.9 kN/m is the highest level in the previous works of this system. Moreover, the proposed fabrication way of the IMN structure is facile and scalable, which is highly expected to be an efficient strategy for development of structured biodegradable polymers with excellent comprehensive properties.

Toward Excellent Energy Storage Performance via Well-Aligned and Isolated Interfaces in Multicomponent Polypropylene-Based All-Organic Polymer Dielectric Films

Polypropylene (PP) serves as an excellent commercialized polymer dielectric film owing to its high breakdown strength, excellent self-healing ability, and flexibility. However, its low dielectric constant causes the large volume of the capacitor. Constructing multicomponent polypropylene-based all-organic polymer dielectric films is a facile strategy for achieving high energy density and efficiency simultaneously. Thereinto, the interfaces between the components become the key factors that determine the energy storage performance of the dielectric films. In this work, we propose to fabricate high-performance polyamide 513 (PA513)/PP all-organic polymer dielectric films via the construction of abundant well-aligned and isolated nanofibrillar interfaces. Laudably, a significant enhancement in the breakdown strength is achieved from 573.1 MV/m of pure PP to 692.3 MV/m with 5 wt % of PA513 nanofibrils. Besides, a maximum discharge energy density of about 4.4 J/cm² is realized with 20 wt % of PA513 nanofibrils, which is about 1.6-folds higher than pure PP. Simultaneously, the energy efficiency of samples with modulated interfaces maintains higher than 80% up to 600 MV/m, which is much higher than pure PP of about 40.7% at 550 MV/m. This work provides a new strategy to fabricate high-performance multicomponent all-organic polymer dielectric films on an industrial scale.

Approaches in Sustainable, Biobased Multilayer Packaging Solutions

The depletion of fossil resources and the growing demand for plastic waste reduction has put industries and academic researchers under pressure to develop increasingly sustainable packaging solutions that are both functional and circularly designed. In this review, we provide an overview of the fundamentals and recent advances in biobased packaging materials, including new materials and techniques for their modification as well as their end-of-life scenarios. We also discuss the composition and modification of biobased films and multilayer structures, with particular attention to readily available drop-in solutions, as well as coating techniques. Moreover, we discuss end-of-life factors, including sorting systems, detection methods, composting options, and recycling and upcycling possibilities. Finally, regulatory aspects are pointed out for each application scenario and end-of-life option. Moreover, we discuss the human factor in terms of consumer perception and acceptance of upcycling.

Lightweight and High Impact Toughness PP/PET/POE Composite Foams Fabricated by In Situ Nanofibrillation and Microcellular Injection Molding

Polypropylene (PP) has become the most promising and candidate material for fabricating lightweight products. Microcellular injection molding (MIM) is a cost-effective technology for manufacturing porous plastic products. However, it is still challenging to fabricate high-performance PP microcellular components. Herein, we reported an efficient strategy to produce lightweight and high impact toughness foamed PP/polyethylene terephthalate (PET)/polyolefin-based elastomer (POE) components by combining in situ fibrillation (INF) and MIM technologies. First, the INF composite was prepared by integrating twin-screw compounding with melt spinning. SEM analysis showed PET nanofibrils with a diameter of 258 nm were achieved and distributed uniformly in the PP due to the POE's inducing elaboration effect. Rheological and DSC analysis demonstrated PET nanofibrils pronouncedly improved PP's viscoelasticity and crystal nucleation rate, respectively. Compared with PP foam, INF composite foam showed more stretched cells in the skin layer and refined spherical cells in the core layer. Due to the synergistic toughening effect of PET nanofibrils and POE elastic particles, the impact strength of INF composite foams was 295.3% higher than that of PP foam and 191.2% higher than that of melt-blended PP/PET foam. The results gathered in this study reveal potential applications for PP based INF composite foams in the manufacturing of lightweight automotive products with enhanced impact properties.

Dynamic Sustainable Polyimide Film Combining Hardness with Softness via a "Mimosa-Like" Bionic Strategy

Dielectric polyimides (PIs) are ubiquitous as insulation in electrical power systems and electronic devices. Generally, dynamic polyimide is required to solve irreversible failure processes of electrical or mechanical damage, for example, under high temperature, pressure, and field strength. The challenge lies in the design of the molecular structure of rigid polyimide to achieve dynamic reversibility. Herein, a low-molecular-weight polyimide gene unit is designed to crosslink with polyimide ligase to prepare the smart film. Interestingly, due to the variability of gene unit and ligase combinations, the polyimide films combining hardness with softness are designed into three forms via a "Mimosa-like" bionic strategy to adapt to different application scenarios. Meanwhile, the films have good degradation efficiency, excellent recyclability, and can be self-healable, which makes them reuse. Clearly, the films can be used in the preparation of ultrafast sensors with a response time ≈0.15 s and the application of corona-resistant films with 100% recovery. Furthermore, the construction of polyimide and carbon-fiber-reinforced composites (CFRCs) has been verified to apply to the worse environment. Nicely, the composites have the property of multiple cycles and the non-destructive recycle rate of carbon fiber (CF) is as high as 100%. The design idea of preparing high-strength dynamic polyimide by crosslinking simple polyimide gene unit with ligase could provide a good foundation and a clear case for the sustainable development of electrical and electronic polyimides, from the perspective of Mimosa bionics.

Morphology and Properties of Polyolefin Elastomer/Polyamide 6/Poly(lactic Acid) In Situ Special-Shaped Microfibrillar Composites: Influence of Viscosity Ratio

In Situ microfibrillation is an easy and economical processing method, which has drawn wide concern in recent years. In Situ special-shaped microfibrillar composites, which with poly(lactic acid)/polyamide 6 (PA6/PLA) together formed special-shaped microfibrils in polyolefin elastomer (POE) matrix, were successfully prepared by using multistage stretching extrusion technology. Four types of PA6 with different viscosity were utilized to investigate the effect of viscosity ratio of PA6 to PLA on the structure evolution of special-shaped microfibrils and the mechanical properties of POE/(PA6/PLA) composites. The morphological observation showed that the viscosity ratio was closely associated to the size and shape of PA6 and greatly affected the microfibrillar morphology of PLA/PA6. When the viscosity ratio of PA6 to PLA was less than 2.2, the “gourd-skewers-like” structure microfibrils were obtained. When the viscosity ratio of PA6/PLA to 14.2 was further increased, the “trepang” structure microfibrils were dominant. The “gourd skewers” structure microfibrils were favorable to improvement the tensile strength, Young’s modulus, and viscoelastic properties of POE/(PA6/PLA) blends compared to the “trepang” structure microfibrils. In addition, the morphology of microfibrils exhibited a negligible effect on the melting and crystallization temperature and crystallization degree of PLA and POE matrix. This work provides a new strategy for designing the in situ special-shaped microfibrillar composites with improved mechanical properties.

Hybrid Nanofibrous Composites with Anisotropic Mechanics and Architecture for Tendon/Ligament Repair and Regeneration

Rupture of tendons and ligaments (T/L) is a major clinical challenge due to T/L possess anisotropic mechanical properties and hierarchical structures. Here, to imitate these characteristics, an approach is presented by fabricating hybrid nanofibrous composites. First, hybrid fiber-reinforced yarns are fabricated via successively electrospinning poly(L-lactide-co-ε-caprolactone) (PLCL) and gelatin (Ge) nanofibers onto polyethylene terephthalate (PET) fibers to improve biodurability and biocompatibility. Then, by comparing different manufacturing methods, the knitted structure succeeds in simulating anisotropic mechanical properties, even being stronger than natural ligaments, and possessing comfort compliance superior to clinically used ligament advanced reinforcement system (LARS) ligament. Moreover, after inoculation with tendon-derived stem cells and transplantation in vivo, hybrid nanofibrous composites are integrated with native tendons to guide surrounding tissue ingrowth due to the highly interconnected and porous structure. The knitted hybrid nanofibrous composites are also ligamentized and remodeled in vivo to promote tendon regeneration. Specifically, after the use of optimized anisotropic hybrid nanofibrous composites to repair tendon, the deposition of tendon-associated extracellular matrix proteins is more significant. Thus, this study indicates a strategy of manufacturing anisotropic hybrid nanofibrous composites with superior mechanical properties and good histocompatibility for clinical reconstruction.

The Multiple Uses of Polypropylene/Polyethylene Terephthalate Microfibrillar Composite Structures to Support Waste Management-Composite Processing and Properties

Composite processing and subsequent characterization of microfibrillar composites (MFC) were the focus of this work. Compression molding of wound MFC filaments was used to fabricate MFC composites. The MFC composites were composed of polypropylene (PP) as matrix materials and polyethylene terephthalate (PET) as reinforcement fibers. The PP/PET blends were mixed with PET contents ranging from 22 wt% to 45 wt%. The effect of processing parameters, pressure, temperature, and holding time on the mechanical properties of the MFCs was investigated. Tensile tests were conducted to optimize the processing parameter and weight ratio of PET. Tensile strength and modulus increased with the increase in PET content. PP/45 wt% PET MFC composites properties reached the value of PP/30 wt% GF. Falling weight tests were conducted on MFC composites. The MFC composites showed the ability to absorb the impact energy compared to neat PP and PP/30 wt% GF.

The Feasibility of Using the MFC Concept to Upcycle Mixed Recycled Plastics

Several mixed recycled plastics, namely, mixed bilayer polypropylene/poly (ethylene terephthalate) (PP/PET) film, mixed polyolefins (MPO) and talc-filled PP were selected for this study and used as matrices for the preparation of microfibrillar composites (MFCs) with PET as reinforcement fibres. MFCs with recycled matrices were successfully prepared by a three-step processing (extrusion—cold drawing—injection moulding), although significant difficulties in processing were observed. Contrary to previous results with virgin PP, no outstanding mechanical properties were achieved; they showed little or almost no improvement compared to the properties of unreinforced recycled plastics. SEM characterisation showed a high level of PET fibre coalescence present in the MFC made from recycled PP/PET film, while in the other MFCs, a large heterogeneity of the microstructure was identified. Despite these disappointing results, the MFC concept remains an interesting approach for the upcycling of mixed polymer waste. However, the current study shows that the approach requires further in-depth investigations which consider various factors such as viscosity, heterogeneity, the presence of different additives and levels of degradation.

Development of Polypropylene/Polyethylene Terephthalate Microfibrillar Composites Filament to Support Waste Management

The concept of microfibrillar composites (MFCs) is adopted to produce composites of polyethylene terephthalate (PET) fiber-reinforced polypropylene (PP) materials. The two polymers were dry mixed with PET content ranging from 22 to 45 wt%. The PET has been used as a reinforcement to improve the mechanical properties of composites. The relationship between the morphology of the MFC structure and the mechanical behavior of the MFC filament was investigated. Analysis of the structure and mechanical behavior helped to understand the influence of the stretching ratio, extruder-melt temperature, stretching-chamber temperature, and filament speed.