Wood Polymer Composite Based on Poly-3-hydroxybutyrate-3-hydroxyvalerate (PHBV) and Wood Flour-The Process Optimization of the Products

This study involved the optimization of the molded pieces manufacturing process from a poly-3-hydroxybutyrate-co-3-hydroxyvalerate biocomposite containing 30% wood flour by mass. The amount of wood flour and preliminary processing parameters were determined on the basis of preliminary tests. The aim of the optimization was to find the configuration of important parameters of the injection process to obtain molded pieces of good quality, in terms of aesthetics, dimensions, and mechanical properties. The products tested for quality were dog bone specimens. The biocomposite was produced using a single-screw extruder, whereas molded pieces were made using an injection molding process. The Taguchi method was applied to optimize the injection molding parameters, which determine the products quality. Control factors were selected at three levels. The L27 orthogonal plan was used. For each set of input parameters from this plan, four processing tests were performed. The sample weight, shrinkage, elongation at break, tensile strength, and Young's modulus were selected to assess the quality of the molded parts. As a result of the research, the processing parameters of the tested biocomposite were determined, enabling the production of good-quality molded pieces. No common parameter configuration was found for different optimization criteria. Further research should focus on finding a different range of technological parameters. At the same time, it was found that the range of processing parameters of the produced biocomposite, especially processing temperature, made it possible to use it in the Wood Polymer Composites segment.

Biodegradable blends from bacterial biopolyester PHBV and bio-based PBSA: Study of the effect of chain extender on the thermal, mechanical and morphological properties

Being aware of the global problem of plastic pollution, our society is claiming new bioplastics to replace conventional polymers. Balancing their mechanical performance is required to increase their presence in the market. Brittleness of bacterial poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) was attempted to be decreased by melt blending with flexible starch-based poly(butylene succinate-co-butylene adipate) (PBSA). An epoxy-functionalized chain extender was used to enhance interaction between both immiscible biopolyesters. Mechanical performance, morphology, rheology, and crystallization behavior of injection-molded PHBV-PBSA blends (70-30, 50-50, and 30-70 wt%) were assessed in the presence and absence of the chain extender. Crystallization of PHBV was hindered, which was reflected in the improvement of mechanical properties. When PBSA >50 %, the homogeneity of results increased within the same sample while for PHBV-PBSA 70-30 wt% the elongation was 45 % higher. During the flexural test, it changed from brittle to non-breakable. The additive did not change the type of morphology developed by each blend nor the toughening mechanisms, so impact strength was barely affected. However, it reduced the size of dispersed phase domains due to a viscosity change, improving their processability. The higher the PHBV in the blend, the higher the effect of the chain extender.

Kraft Lignin/Tannin as a Potential Accelerator of Antioxidant and Antibacterial Properties in an Active Thermoplastic Polyester-Based Multifunctional Material

This research focuses on key priorities in the field of sustainable plastic composites that will lead to a reduction in CO₂ pollution and support the EU’s goal of becoming carbon neutral by 2050. The main challenge is to develop high-performance polyphenol-reinforced thermoplastic composites, where the use of natural fillers replaces the usual chemical additives with non-toxic ones, not only to improve the final performance but also to increase the desired multifunctionalities (structural, antioxidant, and antibacterial). Therefore, poly (lactic acid) (PLA) composites based on Kraft lignin (KL) and tannin (TANN) were investigated. Two series of PLA composites, PLA-KL and PLA-TANN, which contained natural fillers (0.5%, 1.0%, and 2.5% (w/w)) were prepared by hot melt extrusion. The effects of KL and TANN on the PLA matrices were investigated, especially the surface physicochemical properties, mechanical properties, and antioxidant/antimicrobial activity. The surface physicochemical properties were evaluated by measuring the contact angle (CA), roughness, zeta potential, and nanoindentation. The results of the water contact angle showed that neither KL nor TANN caused a significant change in the wettability, but only a slight increase in the hydrophilicity of the PLA composites. The filler loading, the size of the particles with their available functional groups on the surfaces of the PLA composites, and the interaction between the filler and the PLA polymer depend on the roughness and zeta potential behavior of the PLA-KL and PLA-TANN composites and ultimately improve the surface mechanical properties. The antioxidant properties of the PLA-KL and PLA-TANN composites were determined using the DPPH (2,2′-diphenyl-1-picrylhydrazyl) test. The results show an efficient antioxidant behavior of all PLA-KL and PLA-TANN composites, which increases with the filler content. Finally, the KL- and PLA-based TANN have shown resistance to the Gram-negative bacteria, E. coli, but without a correlation trend between polyphenol filler content and structure.

Artificial Ageing, Chemical Resistance, and Biodegradation of Biocomposites from Poly(Butylene Succinate) and Wheat Bran

The results of comprehensive studies on accelerated (artificial) ageing and biodegradation of polymer biocomposites on PBS matrix filled with raw wheat bran (WB) are presented in this paper. These polymer biocomposites are intended for the manufacture of goods, in particular disposable packaging and disposable utensils, which decompose naturally under the influence of biological agents. The effects of wheat bran content within the range of 10–50 wt.% and extruder screw speed of 50–200 min⁻¹ during the production of biocomposite pellets on the resistance of the products to physical, chemical, and biological factors were evaluated. The research included the determination of the effect of artificial ageing on the changes of structural and thermal properties by infrared spectra (FTIR), differential scanning calorimetry (DSC), and thermogravimetric analysis (TG). They showed structural changes—disruption of chains within the ester bond, which occurred in the composition with 50% bran content as early as after 250 h of accelerated ageing. An increase in the degree of crystallinity with ageing was also found to be as high as 48% in the composition with 10% bran content. The temperature taken at the beginning of weight loss of the compositions studied was also lowered, even by 30 °C at the highest bran content. The changes of mechanical properties of biocomposite samples were also investigated. These include: hardness, surface roughness, transverse shrinkage, weight loss, and optical properties: colour and gloss. The ageing hardness of the biocomposite increased by up to 12%, and the surface roughness (R_a) increased by as much as 2.4 µm at the highest bran content. It was also found that ageing causes significant colour changes of the biocomposition (ΔE = 7.8 already at 10% bran content), and that the ageing-induced weight loss of the biocomposition of 0.31–0.59% is lower than that of the samples produced from PBS alone (1.06%). On the other hand, the transverse shrinkage of moldings as a result of ageing turned out to be relatively small, at 0.05%–0.35%. The chemical resistance of biocomposites to NaOH and HCl as well as absorption of polar and non-polar liquids (oil and water) were also determined. Biodegradation studies were carried out under controlled conditions in compost and weight loss of the tested compositions was determined. The weight of samples made from PBS alone after 70 days of composting decreased only by 4.5%, while the biocomposition with 10% bran content decreased by 15.1%, and with 50% bran, by as much as 68.3%. The measurements carried out showed a significant influence of the content of the applied lignocellulosic fillers (LCF) in the form of raw wheat bran (WB) on the examined properties of the biocompositions and the course of their artificial ageing and biodegradation. Within the range under study, the screw speed of the extruder during the production of biocomposite pellets did not show any significant influence on most of the studied properties of the injection mouldings produced from it.

Analysis of Selected Properties of Injection Moulded Sustainable Biocomposites from Poly(butylene succinate) and Wheat Bran

The paper presents a procedure of the manufacturing and complex analysis of the properties of injection mouldings made of polymeric composites based on the poly(butylene succinate) (PBS) matrix with the addition of a natural filler in the form of wheat bran (WB). The scope of the research included measurements of processing shrinkage and density, analysis of the chemical structure, measurements of the thermal and thermo-mechanical properties (Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TG), Heat Deflection Temperature (HDT), and Vicat Softening Temperature (VST)), and measurements of the mechanical properties (hardness, impact strength, and static tensile test). The measurements were performed using design of experiment (DOE) methods, which made it possible to determine the investigated relationships in the form of polynomials and response surfaces. The mass content of the filler and the extruder screw speed during the production of the biocomposite granulate, which was used for the injection moulding of the test samples, constituted the variable factors adopted in the DOE. The study showed significant differences in the processing, thermal, and mechanical properties studied for individual systems of the DOE.

Efficiency of Twin-Screw Extrusion of Biodegradable Poly (Butylene Succinate)-Wheat Bran Blend

Unmodified poly (butylene succinate) (PBS) is characterized by very good processability; however, after the incorporation of various fillers of plant origin, its processing becomes much more complicated and its properties are significantly affected. Detailed studies of the processing aspects of PBS/wheat bran (WB) biocomposition are lacking, despite the addition of WB having a significant impact on both the production efficiency and the properties of end products. This research paper presents test results of the co-rotating twin-screw extrusion processing of a biodegradable polymer blend, the matrix of which was PBS, with WB as the filler. In undertaking this task, we examined the impact of extruder screw rotational speed and WB content on the characteristics of extrusion processing, as well as on certain thermal, physical, structural and processing properties of the obtained blend. The WB introduced to the blend was in the form of a selected fraction with particles smaller than 0.2 mm. The measurements were conducted using the Design of Experiment (DOE) methods, which enabled establishing the studied relationships in the form of polynomials and response surfaces. The determined extrusion process characteristics covered the impact of screw rotational speed and WB content on the mass flow rate of the processed blend and its pressure, the screw drive torque and specific energy consumption. The studies of the obtained polymer blend included determining the impact of the aforementioned variable factors on the melt flow rate (MFR) index, chemical structure (FTIR), thermal properties (differential scanning calorimetry (DSC), thermogravimetry (TG), derivative thermogravimetry (DTG)), p-v-T relationships, microstructure, density and moisture absorbance. Analysis of variance (ANOVA) was used to assess the effect of individual variable factors. The results of this work are presented, inter alia, using Pareto charts of standardized effects, which illustrate the influence of individual terms of the determined regression equations on the studied quantity.

Recent advances in additive manufacturing of engineering thermoplastics: challenges and opportunities

There are many limitations within three-dimensional (3D) printing that hinder its adaptation into industries such as biomedical, cosmetic, processing, automotive, aerospace, and electronics. The disadvantages of 3D printing include the inability of parts to function in weight-bearing applications, reduced mechanical performance from anisotropic properties of printed products, and limited intrinsic material performances such as flame retardancy, thermal stability, and/or electrical conductivity. Many of these shortcomings have prevented the adaptation of 3D printing into product development, especially with few novel researched materials being sold commercially. In many cases, high-performance engineering thermoplastics (ET) provide a basis for increased thermal and mechanical performances to address the shortcomings or limitations of both selective laser sintering and extrusion 3D printing. The first strategy to combat these limitations is to fabricate blends or composites. Novel printing materials have been implemented to reduce anisotropic properties and losses in strength. Additives such as flame retardants generate robust materials with V0 flame retardancy ratings, and compatibilizers can improve thermal or dimensional stability. To serve the electronic industry better, the addition of carbon black at only 4 wt%, to an ET matrix has been found to improve the electrical conductivity by five times the magnitude. Surface modifications such as photopolymerization have improved the usability of ET in automotive applications, whereas the dynamic chemical processes increased the biocompatibility of ET for medical device materials. Thermal resistant foam from polyamide 12 and fly ash spheres were researched and fabricated as possible insulation materials for automotive industries. These works and others have not only generated great potential for additive manufacturing technologies, but also provided solutions to critical challenges of 3D printing.

Mechanical Strength, Thermal Conductivity and Electrical Breakdown of Kenaf Core Fiber/Lignin/Polypropylene Biocomposite

Mechanical strength, thermal conductivity and electrical breakdown of polypropylene/lignin/kenaf core fiber (PP/L/KCF) composite were studied. PP/L, PP/KCF and PP/L/KCF composites with different fiber and lignin loading was prepared using a compounding process. Pure PP was served as control. The results revealed that tensile and flexural properties of the PP/L/KCF was retained after addition of lignin and kenaf core fibers. Thermal stability of the PP composites improved compared to pure PP polymer. As for thermal conductivity, no significant difference was observed between PP composites and pure PP. However, PP/L/KCF composite has higher thermal diffusivity. All the PP composites produced are good insulating materials that are suitable for building. All PP composites passed withstand voltage test in air and oil state as stipulated in IEC 60641-3 except PP/L in oil state. SEM micrograph showed that better interaction and adhesion between polymer matrix, lignin and kenaf core fibers was observed and reflected on the better tensile strength recorded in PP/L/KCF composite. This study has successfully filled the gap of knowledge on using lignin and kenaf fibers as PP insulator composite materials. Therefore, it can be concluded that PP/Lignin/KCF has high potential as an insulating material.

Electrical and Optical Properties of Silicon OxideLignin Polylactide (SiO2-L-PLA)

This paper presents a study on the electrical properties of new polylactide-based nanocomposites with the addition of silicon-dioxide–lignin nanoparticles and glycerine as a plasticizer. Four samples were prepared with nanoparticle mass fractions ranging between 0.01 to 0.15 (0.01, 0.05, 0.10, and 0.15), and three samples were prepared without nanoparticle filler—unfilled and unprocessed polylactide, unfilled and processed polylactide, and polylactide with Fusabond and glycerine. All samples were manufactured using the melt mixing extrusion technique and injection molding. Only the unfilled and unprocessed PLA sample was directly prepared by injection molding. Dielectric properties were studied with broadband spectroscopy in a frequency range from 0.1 Hz to 1 MHz in 55 steps designed on a logarithmic scale and a temperature range from 293.15 to 333.15 K with a 5 K step. Optical properties of nanocomposites were measured with UV-VIS spectroscopy at wavelengths from 190 to 1100 nm. The experimental data show that the addition of silicon-dioxide–lignin and glycerine significantly affected the electrical properties of the studied nanocomposites based on polylactide. Permittivity and electrical conductivity show a significant increase with an increasing concentration of nanoparticle filler. The optical properties are also affected by nanofiller and cause an increase in absorbance as the number of silicon-dioxide–lignin nanoparticles increase.

Triply Biobased Thermoplastic Composites of Polylactide/Succinylated Lignin/Epoxidized Soybean Oil

Soybean oil is beneficial to improve the compatibility between polylactide (PLA) and succinylated lignin (SAL), which leads to the preparation of a host of biobased composites containing PLA, SAL, and epoxidized soybean oil (ESO). The introduction of SAL and ESO enables the relatively homogeneous morphology and slightly better miscibility obtained from triply PLA/SAL/ESO composites after dynamic vulcanization compared with unmodified PLA. The rigidity of the composites is found to decline gradually due to the addition of flexible molecular chains. According to the reaction between SAL and ESO, the T_g of PLA/SAL/ESO composites is susceptible to the movement of flexible molecular chains. The rheological behaviors of PLA/SAL/ESO under different conditions, i.e., temperature and frequency, exhibit a competition between viscidity and elasticity. The thermal stability of the composites displays a slight decrease due to the degradation of SAL and then the deterioration of ESO. The elongation at break and notched impact strength of the composites with augmentation of ESO increase by 12% and 0.5 kJ/m², respectively. The triply biobased PLA/SAL/ESO composite is thus deemed as a bio-renewable and environmentally friendly product that may find vast applications.

Functional MgO-Lignin Hybrids and Their Application as Fillers for Polypropylene Composites

Inorganic-organic hybrids are a group of materials that have recently become the subject of intense scientific research. They exhibit some of the specific properties of both highly durable inorganic materials (e.g., titanium dioxide, zinc) and organic products with divergent physicochemical traits (e.g., lignin, chitin). This combination results in improved physicochemical, thermal or mechanical properties. Hybrids with defined characteristics can be used as fillers for polymer composites. In this study, three types of filler with different MgO/lignin ratio were used as fillers for polypropylene (PP). The effectiveness of MgO-lignin binding was confirmed using Fourier transform infrared spectroscopy. The fillers were also tested in terms of thermal stability, dispersive-morphological properties as well as porous structure. Polymer composites containing 3 wt.% of each filler were subjected to wide angle X-ray diffraction tests, differential scanning calorimetry and microscopic studies to define their structure, morphology and thermal properties. Additionally, tensile tests of the composites were performed. It was established that the composition of the filler has a significant influence on the crystallization of polypropylene-either spherulites or transcrystalline layers were formed. The value of Young's modulus and tensile strength remained unaffected by filler type. However, composites with hybrid fillers exhibited lower elongation at break than unfilled polypropylene.

Effect of Lignin Plasticization on Physico-Mechanical Properties of Lignin/Poly(Lactic Acid) Composites

Kraft lignin (KL) or plasticized KL (PKL)/poly(lactic acid) (PLA) composites, containing different lignin contents and with and without the coupling agent, were prepared in this study using twin-screw extrusion at 180 °C. Furthermore, ε-caprolactone and polymeric diphenylmethane diisocyanate (pMDI) were used as a plasticizer of KL and a coupling agent to improve interfacial adhesion, respectively. It was found that lignin plasticization improved lignin dispersibility in the PLA matrix and increased the melt flow index due to decrease in melt viscosity. The tensile strength of KL or PKL/PLA composites was found to decrease as the content of KL and PKL increased in the absence of pMDI, and increased due to pMDI addition. The existence of KL and PKL in the composites decreased the thermal degradation rate against the temperature and increased char residue. Furthermore, the diffusion coefficient of water in the composites was also found to decrease due to KL or PKL addition.

Optimization of Maleinized Linseed Oil Loading as a Biobased Compatibilizer in Poly(Butylene Succinate) Composites with Almond Shell Flour

Green composites of poly(butylene succinate) (PBS) were manufactured with almond shell flour (ASF) by reactive compatibilization with maleinized linseed oil *MLO) by extrusion and subsequent injection molding. ASF was kept constant at 30 wt %, while the effect of different MLO loading on mechanical, thermal, thermomechanical, and morphology properties was studied. Uncompatibilized PBS/ASF composites show a remarkable decrease in mechanical properties due to the nonexistent polymer‒filler interaction, as evidenced by field emission scanning electron microscopy (FESEM). MLO provides a plasticization effect on PBS/ASF composites but, in addition, acts as a compatibilizer agent since the maleic anhydride groups contained in MLO are likely to react with hydroxyl groups in both PBS end chains and ASF particles. This compatibilizing effect is observed by FESEM with a reduction of the gap between the filler particles and the surrounding PBS matrix. In addition, the T_g of PBS increases from −28 °C to −12 °C with an MLO content of 10 wt %, thus indicating compatibilization. MLO has been validated as an environmentally friendly additive to PBS/ASF composites to give materials with high environmental efficiency.

Bio-poly(butylene succinate) and Its Composites with Grape Pomace: Mechanical Performance and Thermal Properties

Biocomposites from bio-based poly(butylene succinate) (BioPBS) and grape pomace (GP) were made by melt extrusion-injection molding. Grape pomace is a low value byproduct from the wine industry that can be utilized as a filler to increase its value and to decrease the amount of polymer required in a composite blend. Experiments were performed with up to 50% grape pomace by weight. Composites were also compatibilized with in situ manufactured maleic anhydride-grafted BioPBS (MA-g-BioPBS). Flexural and impact strength were improved with the addition of GP up to the addition of 50 wt % GP, suggesting that at this loading the formulation reached threshold performance. The blend of (57:40:3) BioPBS/GP/MA-g-BioPBS showed the best overall performance in terms of a balance of both mechanical properties and thermal properties. The increase in impact resistance confirmed that the GP acted as a reinforcing phase. The addition of 3 wt % MA-g-BioPBS in samples containing 40 wt % of grape pomace resulted in improvements of 28.4 and 59% in flexural and impact strengths, respectively, compared to neat BioPBS. Heat distortion temperature increased with the addition of grape pomace by 14.3% in a blend combination of 57% BioPBS, 40% grape pomace, and 3% MA-g-BioPBS compared to neat BioPBS. Scanning electron microscopy results show improved interfacial adhesion with the addition of MA-g-BioPBS and thermogravimetric analysis results prove that the GP is thermally stable under the processing conditions. This study shows that GP can be successfully incorporated into a BioPBS matrix to create biocomposites with improved thermal and mechanical properties.

Lignin and holocellulose from pecan nutshell as reinforcing fillers in poly (lactic acid) biocomposites

Lignocellulose from agro-food biowaste represents a valuable source of cost-effective structural fillers for wholly renewable polymer composites. In this work, pecan (Carya illinoinensis) nutshell (NS) fiber and its structural components, holocellulose (HC) and acid insoluble lignin (AIL), were isolated, characterized and used as reinforcing fillers to manufacture poly(lactic acid) (PLA) based biocomposites. Thermal, morphological and mechanical properties of the prepared materials were analyzed. NS and HC acted as heterogeneous nucleating agents, potentially able to control PLA physical aging. Moreover, they significantly enhanced the viscoelastic response of PLA, mainly restricting the melt molecular mobility due to hydrodynamic effects and the formation of a three-dimensional particulate network. Flexural tests demonstrated that HC induced a 25% increase in modulus compared to the plain polymer. AIL, conversely, conferred higher ductility to the PLA matrix producing an increase in stress and strain at break of 55% and 65%, respectively. Finally, all the biocomposites showed lower resilience with respect to plain PLA due to the lack of chemical adhesion between filler and matrix. These results emphasize the potential of NS as a source of reinforcing filler in polymer-based biocomposites.

Effect of compatibilizer on the properties of PBS/lignin composites prepared via a vane extruder

Maleic anhydride (MAH) grafted polymers and silanes have been used as the compatibilizer in poly (butylene succinate)/lignin (PBS/lignin) composites. Compatibilized composites were fabricated by a novel vane extruder (VE). The effects of MAH grafted and coupling agent on the mechanical, thermal property, rheological property and water absorption of PBS/lignin were investigated. The results showed that the use of MAH grafted polymers and silanes resulted in significant improvements in flexural property, tensile modulus and tensile strength. Furthermore, MAH grafted polymers and silanes exhibited some improvement on the properties of vicat softening temperature as well as water absorption. The composites treated by MAH grafted polymers and silanes showed non-Newtonian behaviors from rheological tests. A better interfacial adhesion between lignin and matrix was observed from the scanning electron microscopy (SEM) of the compatibilized composites.