Bridging the gap between rubbers and plastics: a review on thermoplastic polyolefin elastomers

Optimizing Processing Parameters for NR/EBC Thermoplastic Vulcanizates: A Comprehensive Full Factorial Design of Experiments (DOE) Strategy

This research explores the development of thermoplastic vulcanizate (TPV) blends derived from natural rubber (NR) and ethylene-butene copolymer (EBC) using a specific blend ratio and melt mixing technique. A comprehensive full factorial design of experiments (DOE) methodology is employed to optimize the processing parameters. TPVs are produced through dynamic vulcanization, combining rubber crosslinking and melt blending within a thermoplastic matrix under high temperatures and shear. The physico-mechanical properties of these TPVs are then analyzed. The objective is to enhance their mechanical performance by assessing the influence of blend ratio, mixing temperature, rotor speed, and mixing time on crucial properties, including tensile strength, elongation at break, compression set, tear strength, and hardness. Analysis of variance (ANOVA) identifies the optimal processing conditions that significantly improve material performance. Validation is achieved through atomic force microscopy (AFM), confirming the phase-separated structure and, thus, the success of dynamic vulcanization. Rubber process analyzer (RPA) and dynamic mechanical analyzer (DMA) assessments provide insights into the viscoelastic behavior and dynamic mechanical responses. Deconvolution analysis of temperature-dependent tan δ peaks reveals intricate microstructural interactions influencing the glass transition temperature (Tg). The optimized TPVs exhibit enhanced stiffness and effective energy dissipation capabilities across a wide temperature range, making them suitable for applications demanding thermal and mechanical load resistance. This study underscores the pivotal role of precise processing control in tailoring the properties of NR/EBC TPVs for specialized industrial uses. It highlights the indispensable contribution of the DOE methodology to TPV optimization, advancing material science and engineering, particularly for industries requiring robust and flexible materials.

Closed-Loop Polymer-to-Polymer Upcycling of Waste Poly (Ethylene Terephthalate) into Biodegradable and Programmable Materials

Poly(ethylene terephthalate) (PET), extensively employed in bottles, film, and fiber manufacture, has generated persistent environmental contamination due to its non-degradable nature. The resolution of this issue requires the conversion of waste PET into valuable products, often achieved through depolymerization into monomers. However, the laborious purification procedures involved in the extraction of monomers pose challenges and constraints on the complete utilization of PET. Herein, a strategy is demonstrated for the polymer-to-polymer upcycling of waste PET into high-value biodegradable and programmable materials named PEXT. This process involves reversible transesterifications dependent on ester bonds, wherein commercially available X-monomers from aliphatic diacids and diols are introduced, utilizing existing industrial equipment for complete PET utilization. PEXT features a programmable molecular structure, delivering tailored mechanical, thermal, and biodegradation performance. Notably, PEXT exhibits superior mechanical performance, with a maximal elongation at break of 3419.2 % and a toughness of 270.79 MJ m-3. These characteristics make PEXT suitable for numerous applications, including shape-memory materials, transparent films, and fracture-resistant stretchable components. Significantly, PEXT allows closed-loop recycling within specific biodegradable analogs by reprograming PET or X-monomers. This strategy not only offers cost-effective advantages in large-scale upcycling of waste PET into advanced materials but also demonstrates its enormous prospect in environmental conservation.

Supersoft Norbornene-Based Thermoplastic Elastomers with High Strength and Upper Service Temperature

With over 6 million tons produced annually, thermoplastic elastomers (TPEs) have become ubiquitous in modern society, due to their unique combination of elasticity, toughness, and reprocessability. Nevertheless, industrial TPEs display a tradeoff between softness and strength, along with low upper service temperatures, typically ≤100 °C. This limits their utility, such as in bio-interfacial applications where supersoft deformation is required in tandem with strength, in addition to applications that require thermal stability (e.g., encapsulation of electronics, seals/joints for aeronautics, protective clothing for firefighting, and biomedical devices that can be subjected to steam sterilization). Thus, combining softness, strength, and high thermal resistance into a single versatile TPE has remained an unmet opportunity. Through de novo design and synthesis of novel norbornene-based ABA triblock copolymers, this gap is filled. Ring-opening metathesis polymerization is employed to prepare TPEs with an unprecedented combination of properties, including skin-like moduli (<100 kPa), strength competitive with commercial TPEs (>5 MPa), and upper service temperatures akin to high-performance plastics (≈260 °C). Furthermore, the materials are elastic, tough, reprocessable, and shelf stable (≥2 months) without incorporation of plasticizer. Structure-property relationships identified herein inform development of next-generation TPEs that are both biologically soft yet thermomechanically durable.

A Review of Polyolefin-Insulation Materials in High Voltage Transmission; From Electronic Structures to Final Products

This review focuses on the use of polyolefins in high-voltage direct-current (HVDC) cables and capacitors. A short description of the latest evolution and current use of HVDC cables and capacitors is first provided, followed by the basics of electric insulation and capacitor functions. Methods to determine dielectric properties are described, including charge transport, space charges, resistivity, dielectric loss, and breakdown strength. The semicrystalline structure of polyethylene and isotactic polypropylene is described, and the way it relates to the dielectric properties is discussed. A significant part of the review is devoted to describing the state of art of the modeling and prediction of electric or dielectric properties of polyolefins with consideration of both atomistic and continuum approaches. Furthermore, the effects of the purity of the materials and the presence of nanoparticles are presented, and the review ends with the sustainability aspects of these materials. In summary, the effective use of modeling in combination with experimental work is described as an important route toward understanding and designing the next generations of materials for electrical insulation in high-voltage transmission.

Chromium Catalysts for Selective Ethylene Oligomerization Featuring Binuclear PNP Ligands

A series of novel binuclear PNP ligands based on the cyclohexyldiamine scaffold were synthesized for this study. The experimental results showed that positioning the two PNP sites at the para-positions of the cyclohexyl framework led to a significant enhancement in the catalytic activity for selective tri/tetramerization of ethylene. The PNP/Cr(acac)3/MAO(methylaluminoxane) catalytic system exhibited relatively high catalytic activity (up to 3887.7 kg·g-1·h-1) in selective ethylene oligomerization with a total selectivity of 84.5% for 1-hexene and 1-octene at 40 °C and 50 bar. The relationship between the ligand structure and ethylene oligomerization performance was further explored using density functional theory calculations.

The Effect of Feeding Sequence on the Structure and Properties of the Ethylene/1-Octene Copolymer in the Semi-Continuous Polymerization Reaction System

The performance of ethylene/1-octene copolymer primarily depends on the microstructure of the polymer chain. This study employed a new method to control the inter-distribution of hexyl chain branches directly on the backbone of the ethylene/1-octene copolymer. Three ethylene/1-octene copolymers with different inter-distributions of hexyl chain branches were synthesized using [Me2Si(C5Me4) (NtBu)] TiCl2 (Ti-CGC) by different feeding sequences in the semi-continuous polymerization reaction system. The three copolymers were named according to the feeding sequence of the materials: ethylene/1-octene/Ti-CGC (EOC), 1-octene/Ti-CGC/ethylene (OCE), and ethylene/Ti-CGC/1-octene (ECO), respectively. The structure and properties of the copolymers were characterized using HT-GPC, 13C-NMR, DSC, WAXD, DMA, MI, and Uniaxial Tension Test. The results showed that the feeding sequence greatly affected the comonomer distribution of the molecular chains, molecular weight, molecular weight distribution, and chemical composition of the copolymers, consequently influencing their thermal performance and mechanical properties. Thus, it is probable that one could obtain an ethylene/1-octene copolymer with designed properties by controlling the feeding sequence during the ethylene/1-octene semi-continuous copolymerization process.

Effect of Carbon Nanoparticles Morphology on the Properties of Poly(styrene-b-isoprene-b-styrene) Elastomer Composites

Though nanomaterials based on carbon have been widely used for the preparation of high-performance polymeric nanocomposites, there are few works focused on the effect of carbon nanoparticle morphology on the performance of corresponding polymer nanocomposites. Therefore, four representative carbon nanoparticles, including fullerene, carbon nanotubes, graphene, and carbon black incorporated poly(styrene-b-isoprene-b-styrene) (SIS) elastomer nanocomposites were fabricated using the solvent casting method. In addition, the effect of carbon nanoparticle morphology on the rheological, mechanical, electrical, and thermal properties of the obtained polymeric nanocomposites was systematically investigated. The results showed that the shape of carbon nanoparticles has a different effect on the properties of the obtained elastomer nanocomposites, which lays the foundation of carbon nanoparticle screening for high-performance polymer nanocomposite construction.

Fully tuneable ethylene-propylene elastomers using a supported permethylindenyl-phenoxy (PHENI*) catalyst

Using a highly active supported permethylindenyl-phenoxy (PHENI*) titanium catalyst, high molecular weight ethylene-propylene (EPM) and ethylene-propylene-diene (EPDM) elastomers are prepared using slurry-phase catalysis. Final copolymer composition was found to reflect the monomer feed ratio in a linear fashion, to access a continuum of material properties with a single catalyst. Post-polymerisation crosslinking of EPDM was also demonstrated in a model sulfur vulcanisation system.

Fracture and mechanical properties of an impact toughened polypropylene composite: modification for automotive dashboard-airbag application

Thermoplastic olefin (TPO) is the principal material for automotive instrument panels and is prone to fracture especially under heavy airbag deployment, which can prevent the airbag deploying properly. Thus, polyolefin elastomer (POE) was introduced to improve impact properties and fracture resistance. Fundamental methods to characterise TPO with the addition of POE are proposed. The influence of POE content on the mechanical properties was examined. With increasing POE content, the storage modulus and glass transition temperature values decreased, and the damping increased due to the POE increasing the polymer chain mobility. The tensile modulus, ultimate tensile strength and yield stress decreased with increasing POE content, while the ductility of the blends significantly increased. Furthermore, the POE reduced hardness and increased energy absorption during impact. In the fracture analysis, the addition of POE content increased the fracture resistance by increasing the crack energy and decreasing the resistance to crack initiation. Fractographic analysis showed how stretched microfibrils in the blends increase the fracture resistance. These results gave a significant indication of the utility of the elastomer in improving some mechanical properties and impact toughness of the interior automotive material to resist an undesired failure or over-fracture in airbag deployment.

Development of nanoparticle-filled polypropylene-based single polymer composite foams

In this study, our focus was on developing and investigating nanoparticle-filled polypropylene-based single polymer composite foams. These composites had porous and nanotube-reinforced matrices, with plain woven polypropylene (PP) fabric as reinforcement. Our main objective was to enhance the energy absorption and stiffness of the single polymer composites (SPCs) by modifying their matrices. We produced SPCs with two different matrices: one of amorphous poly-alpha-olefin (APAO) and one of thermoplastic elastomer (TPE) blended with APAO. We observed that the APAO matrix exhibited better impregnation of the fabric due to its low viscosity, while the composites with the TPE matrix showed significantly better tensile properties. The foaming process applied to the matrices resulted in a substantial increase in energy absorption for the SPCs, while preserving their tensile properties relative to their density. Scanning electron microscope images confirmed that foaming of the APAO matrix was notably more effective, primarily due to its low viscosity. Furthermore, we successfully enhanced the stiffness and tensile properties of the SPCs by nano-reinforcing the matrices with multi-wall carbon nanotubes (MWCNTs). Due to the size of the nanotubes, this reinforcement did not compromise the impact properties of the SPCs. Scanning electron microscope images also demonstrated improved dispersion of the nanotubes within the APAO matrices.

Investigation of the Effect of Hybrid Nanofiller on the Mechanical Performance and Surface Properties of Bio-Based Polylactic Acid/Polyolefin Elastomer (PLA/POE) Blend

Polylactic acid has stood out among bio-based polymers for its usage in the food packaging industry and biomedical fields. Through the melt mixing process, the toughened poly(lactic) acid (PLA) was prepared with polyolefin elastomer (POE), incorporated via various ratios of nanoclay and a fixed amount of nanosilver particles (AgNPs). The correlation between the compatibility and morphology, mechanical properties, and surface roughness of samples with nanoclay was studied. The calculated surface tension and melt rheology confirmed the interfacial interaction demonstrated by droplet size, impact strength, and elongation at break. Each blend sample exhibited matrix-dispersed droplets, and the size of POE droplets steadily dropped with increasing nanoclay content, corresponding to the enhanced thermodynamic affinity between PLA and POE. Scanning electron microscopy (SEM) acknowledged that the inclusion of nanoclay in the PLA/POE blend ameliorated the mechanical performance by preferable localization in the interface of used components. The optimum value of elongation at break was acquired at about 32.44%, where the incorporation of 1 wt.% nanoclay led, respectively, to 171.4% and 24% enhancement rather than the PLA/POE blend with the composition of 80/20 and the virgin PLA. Similarly, the impact strength reached 3.46 ± 0.18 kJ m^-1 as the highest obtained amount, showing the proximity of 23% progress to the unfilled PLA/POE blend. Surface analysis indicated that adding nanoclay caused the augment of surface roughness from 23.78 ± 5.80 µm in the unfilled PLA/POE blend to 57.65 ± 18.2 µm in PLA/POE contained 3 wt.% nanoclay. Rheological measurements implied that organoclay resulted in the strengthening of melt viscosity as well as the rheological parameters such as storage modulus and loss modulus. Han plot further showed that the storage modulus is always higher than the loss modulus in all prepared PLA/POE nanocomposite samples, corresponding to the restriction of polymer chains mobility induced by the formation of strong molecular interaction between nanofillers and polymer chains.

Transition Metal-(μ-Cl)-Aluminum Bonding in α-Olefin and Diene Chemistry

Olefin and diene transformations, catalyzed by organoaluminum-activated metal complexes, are widely used in synthetic organic chemistry and form the basis of major petrochemical processes. However, the role of M−(μ-Cl)−Al bonding, being proven for certain >C=C< functionalization reactions, remains unclear and debated for essentially more important industrial processes such as oligomerization and polymerization of α-olefins and conjugated dienes. Numerous publications indirectly point at the significance of M−(μ-Cl)−Al bonding in Ziegler−Natta and related transformations, but only a few studies contain experimental or at least theoretical evidence of the involvement of M−(μ-Cl)−Al species into catalytic cycles. In the present review, we have compiled data on the formation of M−(μ-Cl)−Al complexes (M = Ti, Zr, V, Cr, Ni), their molecular structure, and reactivity towards olefins and dienes. The possible role of similar complexes in the functionalization, oligomerization and polymerization of α-olefins and dienes is discussed in the present review through the prism of the further development of Ziegler−Natta processes and beyond.

Plastic Waste Management in India: Challenges, Opportunities, and Roadmap for Circular Economy

Plastic waste (PW) is one of the most rapid-growing waste streams in municipal solid waste all over the world. India has become a global player in the plastic value chain. Despite low consumption, domestic generation and imports create a significant burden on the overall waste management system, which requires in-depth understanding of the scenario and pathways that can mitigate the crisis. Although Indian researchers have widely researched technology-related issues in academic papers, a substantial knowledge gap exists in understanding the problem’s depth and possible solutions. This review article focuses on current plastic production, consumption, and waste generation in India. This review article mainly analyzes data and information regarding Indian PW management and highlights some critical issues such as reverse supply chain, effective PW management, source-specific recovery, and PW rules in India. Comprehensively, this review will help to identify implementable strategies for policymakers and research opportunities for future researchers in holistic PW management and recycling in India, focusing on the circular economy and sustainable development goals.