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Gonçalves LFFF, Reis RL, Fernandes EM. Forefront Research of Foaming Strategies on Biodegradable Polymers and Their Composites by Thermal or Melt-Based Processing Technologies: Advances and Perspectives. Polymers (Basel) 2024; 16:1286. [PMID: 38732755 PMCID: PMC11085284 DOI: 10.3390/polym16091286] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/12/2024] [Revised: 04/13/2024] [Accepted: 04/26/2024] [Indexed: 05/13/2024] Open
Abstract
The last few decades have witnessed significant advances in the development of polymeric-based foam materials. These materials find several practical applications in our daily lives due to their characteristic properties such as low density, thermal insulation, and porosity, which are important in packaging, in building construction, and in biomedical applications, respectively. The first foams with practical applications used polymeric materials of petrochemical origin. However, due to growing environmental concerns, considerable efforts have been made to replace some of these materials with biodegradable polymers. Foam processing has evolved greatly in recent years due to improvements in existing techniques, such as the use of supercritical fluids in extrusion foaming and foam injection moulding, as well as the advent or adaptation of existing techniques to produce foams, as in the case of the combination between additive manufacturing and foam technology. The use of supercritical CO2 is especially advantageous in the production of porous structures for biomedical applications, as CO2 is chemically inert and non-toxic; in addition, it allows for an easy tailoring of the pore structure through processing conditions. Biodegradable polymeric materials, despite their enormous advantages over petroleum-based materials, present some difficulties regarding their potential use in foaming, such as poor melt strength, slow crystallization rate, poor processability, low service temperature, low toughness, and high brittleness, which limits their field of application. Several strategies were developed to improve the melt strength, including the change in monomer composition and the use of chemical modifiers and chain extenders to extend the chain length or create a branched molecular structure, to increase the molecular weight and the viscosity of the polymer. The use of additives or fillers is also commonly used, as fillers can improve crystallization kinetics by acting as crystal-nucleating agents. Alternatively, biodegradable polymers can be blended with other biodegradable polymers to combine certain properties and to counteract certain limitations. This work therefore aims to provide the latest advances regarding the foaming of biodegradable polymers. It covers the main foaming techniques and their advances and reviews the uses of biodegradable polymers in foaming, focusing on the chemical changes of polymers that improve their foaming ability. Finally, the challenges as well as the main opportunities presented reinforce the market potential of the biodegradable polymer foam materials.
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Affiliation(s)
- Luis F. F. F. Gonçalves
- 3B’s Research Group, I3Bs–Research Institute on Biomaterials, Biodegradables and Biomimetics, University of Minho, Headquarters of the European Institute of Excellence on Tissue Engineering and Regenerative Medicine, AvePark, Parque de Ciência e Tecnologia, Zona Industrial da Gandra, Barco, 4805-017 Guimarães, Portugal;
- ICVS/3B’s—PT Government Associate Laboratory, Barco, 4805-017 Guimarães, Portugal
| | - Rui L. Reis
- 3B’s Research Group, I3Bs–Research Institute on Biomaterials, Biodegradables and Biomimetics, University of Minho, Headquarters of the European Institute of Excellence on Tissue Engineering and Regenerative Medicine, AvePark, Parque de Ciência e Tecnologia, Zona Industrial da Gandra, Barco, 4805-017 Guimarães, Portugal;
- ICVS/3B’s—PT Government Associate Laboratory, Barco, 4805-017 Guimarães, Portugal
| | - Emanuel M. Fernandes
- 3B’s Research Group, I3Bs–Research Institute on Biomaterials, Biodegradables and Biomimetics, University of Minho, Headquarters of the European Institute of Excellence on Tissue Engineering and Regenerative Medicine, AvePark, Parque de Ciência e Tecnologia, Zona Industrial da Gandra, Barco, 4805-017 Guimarães, Portugal;
- ICVS/3B’s—PT Government Associate Laboratory, Barco, 4805-017 Guimarães, Portugal
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Long H, Xu H, Shaoyu J, Jiang T, Zhuang W, Li M, Jin J, Ji L, Ying H, Zhu C. High-Strength Bio-Degradable Polymer Foams with Stable High Volume-Expansion Ratio Using Chain Extension and Green Supercritical Mixed-Gas Foaming. Polymers (Basel) 2023; 15:polym15040895. [PMID: 36850179 PMCID: PMC9963428 DOI: 10.3390/polym15040895] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/06/2023] [Revised: 01/29/2023] [Accepted: 02/02/2023] [Indexed: 02/15/2023] Open
Abstract
The preparation of biodegradable polymer foams with a stable high volume-expansion ratio (VER) is challenging. For example, poly (butylene adipate-co-terephthalate) (PBAT) foams have a low melt strength and high shrinkage. In this study, polylactic acid (PLA), which has a high VER and crystallinity, was added to PBAT to reduce shrinkage during the supercritical molded-bead foaming process. The epoxy chain extender ADR4368 was used both as a chain extender and a compatibilizer to mitigate the linear chain structure and incompatibility and improve the foamability of PBAT. The branched-chain structure increased the energy-storage modulus (G') and complex viscosity (η*), which are the key factors for the growth of cells, by 1-2 orders of magnitude. Subsequently, we innovatively used the CO2 and N2 composite gas method. The foam-shrinkage performance was further inhibited; the final foam had a VER of 23.39 and a stable cell was obtained. Finally, after steam forming, the results showed that the mechanical strength of the PBAT/PLA blended composite foam was considerably improved by the addition of PLA. The compressive strength (50%), bending strength, and fracture load by bending reached 270.23 kPa, 0.36 MPa, and 23.32 N, respectively. This study provides a potential strategy for the development of PBAT-based foam packaging materials with stable cell structure, high VER, and excellent mechanical strength.
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Affiliation(s)
- Haoyu Long
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Hongsen Xu
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Jingwen Shaoyu
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Tianchen Jiang
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Wei Zhuang
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- National Engineering Technique Research Center for Biotechnique, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- State Key Laboratory of Materials-Oriented Chemical Engineering, Nanjing Tech University, No. 5, Xinmofan Road, Nanjing 210009, China
- Synergetic Innovation Center for Advanced Materials, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- Correspondence: (W.Z.); (C.Z.)
| | - Ming Li
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- National Engineering Technique Research Center for Biotechnique, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- State Key Laboratory of Materials-Oriented Chemical Engineering, Nanjing Tech University, No. 5, Xinmofan Road, Nanjing 210009, China
| | - Junyang Jin
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Lei Ji
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- National Engineering Technique Research Center for Biotechnique, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- State Key Laboratory of Materials-Oriented Chemical Engineering, Nanjing Tech University, No. 5, Xinmofan Road, Nanjing 210009, China
- Synergetic Innovation Center for Advanced Materials, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Hanjie Ying
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- National Engineering Technique Research Center for Biotechnique, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- State Key Laboratory of Materials-Oriented Chemical Engineering, Nanjing Tech University, No. 5, Xinmofan Road, Nanjing 210009, China
- Synergetic Innovation Center for Advanced Materials, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
| | - Chenjie Zhu
- College of Biotechnique and Pharmaceutical Engineering, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- National Engineering Technique Research Center for Biotechnique, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- State Key Laboratory of Materials-Oriented Chemical Engineering, Nanjing Tech University, No. 5, Xinmofan Road, Nanjing 210009, China
- Synergetic Innovation Center for Advanced Materials, Nanjing Tech University, No. 30, Puzhu South Road, Nanjing 211816, China
- Correspondence: (W.Z.); (C.Z.)
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Wang Y, Yang H, Li B, Liu S, He M, Chen Q, Li J. Poly(Butylene Adipate/Terephthalate-Co-Glycolate) Copolyester Synthesis Based on Methyl Glycolate with Improved Barrier Properties: From Synthesis to Structure-Property. Int J Mol Sci 2022; 23:ijms231911074. [PMID: 36232379 PMCID: PMC9570190 DOI: 10.3390/ijms231911074] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2022] [Revised: 09/16/2022] [Accepted: 09/19/2022] [Indexed: 11/16/2022] Open
Abstract
The main problem of manufacturing with traditional biodegradable plastics is that it is more expensive than manufacturing with polymers derived from petroleum, and the application scope is currently limited due to poor comprehensive performance. In this study, a novel biodegradable poly(butylene adipic acid/terephthalate-co-glycolic acid) (PBATGA) copolyester with 25–60% glycolic acid units was successfully synthesized by esterification and polycondensation using cheap coal chemical byproduct methyl glycolate instead of expensive glycolic acid. The structure of the copolyester was characterized by ATR-FTIR, 1H NMR, DSC, and XRD; and its barrier property, water contact angle, heat resistance, and mechanical properties were tested. According to the experiment result, the PBATGA copolyesters showed improved oxygen (O2) and water vapor barrier character, and better hydrophilicity when compared with PBAT. The crystallization peaks of PBATGAs were elevated from 64 °C to 77 °C when the content of the GA unit was 25 mol %, meanwhile, the elongation at the break of PBATGA25 was more than 1300%. These results indicate that PBATGA copolyesters have good potentiality in high O2 and water vapor barrier and degradable packaging material.
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Affiliation(s)
- Yanning Wang
- School of Materials Science and Engineering, Changzhou University, Changzhou 213164, China
| | - Haicun Yang
- School of Materials Science and Engineering, Changzhou University, Changzhou 213164, China
| | - Bingjian Li
- School of Materials Science and Engineering, Changzhou University, Changzhou 213164, China
| | - Shi Liu
- School of Materials Science and Engineering, Changzhou University, Changzhou 213164, China
| | - Mingyang He
- Jiangsu Key Laboratory of Advanced Catalytic Materials and Technology, Changzhou University, Changzhou 213164, China
| | - Qun Chen
- Jiangsu Key Laboratory of Advanced Catalytic Materials and Technology, Changzhou University, Changzhou 213164, China
| | - Jinchun Li
- School of Materials Science and Engineering, Changzhou University, Changzhou 213164, China
- Jiangsu Key Laboratory of Environmentally Friendly Polymeric Materials, National-Local Joint Engineering Research Center of Biomass Refining and High-Quality Utilization, Changzhou University, Changzhou 213164, China
- Correspondence:
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Thermoplastic Starch with Poly(butylene adipate- co-terephthalate) Blends Foamed by Supercritical Carbon Dioxide. Polymers (Basel) 2022; 14:polym14101952. [PMID: 35631835 PMCID: PMC9145724 DOI: 10.3390/polym14101952] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/11/2022] [Revised: 05/06/2022] [Accepted: 05/07/2022] [Indexed: 01/23/2023] Open
Abstract
Starch-based biodegradable foams with a high starch content are developed using industrial starch as the base material and supercritical CO2 as blowing or foaming agents. The superior cushioning properties of these foams can lead to competitiveness in the market. Despite this, a weak melting strength property of starch is not sufficient to hold the foaming agents within it. Due to the rapid diffusion of foaming gas into the environment, it is difficult for starch to maintain pore structure in starch foams. Therefore, producing starch foam by using supercritical CO2 foaming gas faces severe challenges. To overcome this, we have synthesized thermoplastic starch (TPS) by dispersing starch into water or glycerin. Consecutively, the TPS surface was modified by compatibilizer silane A (SA) to improve the dispersion with poly(butylene adipate-co-terephthalate) (PBAT) to become (TPS with SA)/PBAT composite foam. Furthermore, the foam-forming process was optimized by varying the ratios of TPS and PBAT under different forming temperatures of 85 °C to 105 °C, and two different pressures, 17 Mpa and 23 Mpa were studied in detail. The obtained results indicate that the SA surface modification on TPS can influence the great compatibility with PBAT blended foams (foam density: 0.16 g/cm3); whereas unmodified TPS and PBAT (foam density: 0.349 g/cm3) exhibit high foam density, rigid foam structure, and poor tensile properties. In addition, we have found that the 80% TPS/20% PBAT foam can be achieved with good flexible properties. Because of this flexibility, lightweight and environment-friendly nature, we have the opportunity to resolve the strong demands from the packing market.
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