In-depth investigation on the effect and role of cardanol in the compatibilization of PLA/ABS immiscible blends by reactive extrusion

The Development of Poly(lactic acid) (PLA)-Based Blends and Modification Strategies: Methods of Improving Key Properties towards Technical Applications-Review

The widespread use of poly(lactic acid) (PLA) from packaging to engineering applications seems to follow the current global trend. The development of high-performance PLA-based blends has led to the commercial introduction of various PLA-based resins with excellent thermomechanical properties. The reason for this is the progress in the field of major PLA limitations such as low thermal resistance and poor impact strength. The main purpose of using biobased polymers in polymer blends is to increase the share of renewable raw materials in the final product rather than its possible biodegradation. However, in the case of engineering applications, the focus is on achieving the required properties rather than maximizing the percentage of biopolymer. The presented review article discusses the current strategies to optimize the balance of the key features such as stiffness, toughness, and heat resistance of PLA-based blends. Improving of these properties requires molecular structural changes, which together with morphology, crystallinity, and the influence of the processing conditions are the main subjects of this article. The latest research in this field clearly indicates the high potential of using PLA-based materials in highly demanding applications. In the case of impact strength modification, it is possible to obtain values close to 800 J/m, which is a value comparable to polycarbonate. Significant improvement can also be confirmed for thermal resistance results, where heat deflection temperatures for selected types of PLA blends can reach even 130 °C after modification. The modification strategies discussed in this article confirm that a properly conducted process of selecting the blend components and the conditions of the processing technique allows for revealing the potential of PLA as an engineering plastic.

Improving the properties of polylactic acid/polypropylene carbonate blends through cardanol-induced compatibility enhancement

Cardanol (CD) is used as a reactive compatibilizer, and blended with polylactic acid (PLA) and polypropylene carbonate (PPC) resin (70/30(w/w)) to obtain a series of PLA/PPC/CD blends. The systematic study was conducted on the thermal properties, optical properties, rheological properties, mechanical properties, and microscopic morphology of the blend, by varying amounts of CD added to the blends. A detailed explanation and comprehensive analysis of the reaction mechanism between CD and PLA/PPC have been made. The study found that CD acts as a "bridge" between the PLA and PPC, forming the structure of a block copolymer (PLA-b-CD-b-PPC), and the copolymer can greatly improve the compatibility of PLA and PPC. When the amount of CD reaches 8 wt%, only one Tg is observed in the blend, simultaneously, PLA/PPC has already transitioned from a partially compatible system to a completely compatible system. At the same time, the addition of CD does not have any negative impact on the thermal stability of the PLA/PPC blend under processing temperature conditions, and the thermal stability of the PLA/PPC/CD blends can even be improved under extreme conditions. In addition, the addition of CD allows the PLA/PPC/CD blends to maintain a high light transmittance while reducing the opacity of the blend (the light transmittance remains above 92 %, and the opacity is reduced from 37 % to about 24 %), demonstrating excellent optical properties. Moreover, the elongation at break and impact strength of the PLA/PPC/CD blend both show a trend of first increasing and then decreasing with the increase of CD amount. When the CD amount varies within the range of 6- 8 wt%, the blends undergoes a brittle-ductile transition, and its toughness is greatly improved while the rigidity can also meet practical needs. When the amount of CD in the system increases to 12 wt%, the toughness of the blend reaches its peak, and its elongation at break and impact strength reach 513.24 % and 9211.5 J/m2 respectively (increased to 2442.84 % and 270.73 % of the PLA/PPC blend). Concurrently, the fracture surface of the blend exhibits large-scale plastic flow in the direction of the applied force, with marked shear yield phenomena, showing obvious characteristics of tough fracture.

Tailoring PLA/ABS Blends Compatibilized with SEBS-g-MA through Annealing Heat Treatment

In this work, blends based on poly (lactic acid) (PLA)/acrylonitrile-butadiene-styrene (ABS) compatibilized with maleic anhydride-grafted (SEBS-g-MA) were prepared in a co-rotational twin-screw extruder by varying the concentrations of the compatibilizing agent. The influence of the compatibilizing agent on the morphology, mechanical, thermal, thermomechanical, and rheological properties of the prepared materials was analyzed. The effect of annealing on the properties of the blends was also investigated using injection-molded samples. The X-ray diffraction (XRD) results proved that the increments in crystallinity were an effect of annealing in the PLA/ABS/SEBS-g-MA blends, resonating at higher heat deflection temperatures (HDTs). The impact strength of the PLA/ABS blends compatibilized with 10 wt% SEBS-g-MA was significantly increased when compared to the PLA/ABS blends. However, the hardness and elastic modulus of the blends decreased when compared to neat PLA. The refined morphology shown in the scanning electron microscopy (SEM) analyses corroborated the improved impact strength promoted by SEBS-g-MA. The torque rheometer degradation study also supported the increased compatibility between SEBS-g-MA, PLA, and ABS. The TGA results show that the PLA/ABS and PLA/ABS/SEBS-g-MA blends are more thermally stable than the neat PLA polymer at higher temperatures. The results showed that the ideal composition is the heat-treated PLA/ABS/SEBS-g-MA (60/30/10 wt%), given the high impact strength and HDT results. The results of this work in terms of mechanical improvement with the use of compatibilizers and annealing suggest that the PLA/ABS/SEBS-g-MA system can be used in the production of 3D-printing filaments.

An Investigation on the Thermally Induced Compatibilization of SBR and α-Methylstyrene/Styrene Resin

The miscibility between two polymers such as rubbers and performance resins is crucial to achieve given targeted properties in terms of tire performances. To this aim, α-methylstyrene/styrene resin (poly(αMSt-co-St)) are used to modify the viscoelastic behavior of rubbers and to fulfill the requirements of the final applications. The initial aim of this work was to understand the influence of poly(αMSt-co-St) resins blended at different concentrations in a commercial styrene-butadiene rubber (SBR). Interestingly, while studying the viscoelastic properties of SBR blends with poly(αMSt-co-St), crosslinking of the rubber was observed under conditions where it was not expected to happen. Surprisingly, after the crosslinking reactions, the poly(αMSt-co-St) resin was irreversibly miscible with SBR at concentrations far above its immiscibility threshold. A detailed investigation involving characterization technics including solid state nuclear magnetic resonance led to the conclusion that poly(αMSt-co-St) is depolymerizing under heating and can graft onto the chains of SBR. It results in an irreversible compatibilization mechanism between the rubber and the resin.

Modification of Surface Hydrophobicity of PLA/PE and ABS/PE Polymer Blends by ICP Etching and CFx Coating

The flow regime inside the channel of 3D printed microreactors is defined by the surface properties of the channel walls. Polylactide (PLA) and acrylonitrile/butadiene/styrene (ABS) are two polymers that are the most common in additive manufacturing using fused filament fabrication, commonly known as “3D printing”. With the aim of developing new materials for the 3D printing of microreactors whose channel surface hydrophobicity could be modified, PLA and ABS were blended with cheaper and widely used polymers-high-density polyethylene (PE-HD) and low-density polyethylene (PE-LD). Polymer blend surfaces were treated with inductively coupled plasma (ICP) and coated by fluorocarbon-based material (CF_x) plasma deposition treatment in order to modify surface hydrophobicity. It has been shown that the modification of surface morphology of PLA polymer blends can be achieved by ICP etching and CF_x coating, while this was not possible for ABS polymer blends under the conducted treatment conditions. The treated surface of PLA/PE-HD 90/10 showed a contact angle of 121.6° which is 36° higher than the contact angle measured on the untreated surface. Surfaces that have achieved contact angles higher than 120° have an “island like” surface morphology. Samples with higher “islands” showed higher contact angles, that confirmed that the hydrophobicity also depends on the height of the “islands”. Furthermore, it has been found that etching time significantly impacts the contact angle values and surface morphology of the PLA polymer blends, while the CF_x coating time does not have significant impact on the surface properties.

Super tough poly(lactic acid) blends: a comprehensive review

Poly(lactic acid) or poly(lactide) (PLA) is a renewable, bio-based, and biodegradable aliphatic thermoplastic polyester that is considered a promising alternative to petrochemical-derived polymers in a wide range of commodity and engineering applications. However, PLA is inherently brittle, with less than 10% elongation at break and a relatively poor impact strength, which limit its use in some specific areas. Therefore, enhancing the toughness of PLA has been widely explored in academic and industrial fields over the last two decades. This work aims to summarize and organize the current development in super tough PLA fabricated via polymer blending. The miscibility and compatibility of PLA-based blends, and the methods and approaches for compatibilized PLA blends are briefly discussed. Recent advances in PLA modified with various polymers for improving the toughness of PLA are also summarized and elucidated systematically in this review. Various polymers used in toughening PLA are discussed and organized: elastomers, such as petroleum-based traditional polyurethanes (PUs), bio-based elastomers, and biodegradable polyester elastomers; glycidyl ester compatibilizers and their copolymers/elastomers, such as poly(ethylene-co-glycidyl methacrylate) (EGMA), poly(ethylene-n-butylene-acrylate-co-glycidyl methacrylate) (EBA-GMA); rubber; petroleum-based traditional plastics, such as PE and PP; and various biodegradable polymers, such as poly(butylene adipate-co-terephthalate) (PBAT), polycaprolactone (PCL), poly(butylene succinate) (PBS), and natural macromolecules, especially starch. The high tensile toughness and high impact strength of PLA-based blends are briefly outlined, while the super tough PLA-based blends with impact strength exceeding 50 kJ m⁻² are elucidated in detail. The toughening strategies and approaches of PLA based super tough blends are summarized and analyzed. The relationship of the properties of PLA-based blends and their morphological parameters, including particle size, interparticle distance, and phase morphologies, are presented.

PLA is a renewable, bio-based, and biodegradable aliphatic thermoplastic polyester that is considered a promising alternative to petrochemical-derived polymers in a wide range of commodity and engineering applications.

Effect of Poly(styrene-ran-methyl acrylate) Inclusion on the Compatibility of Polylactide/Polystyrene-b-Polybutadiene-b-Polystyrene Blends Characterized by Morphological, Thermal, Rheological, and Mechanical Measurements

A poly(styrene-ran-methyl acrylate) (S-MA) (75/25 mol/mol), synthesized by surfactant-free emulsion copolymerization, was used as a compatibilizer for polystyrene-b-polybutadiene-b-polystyrene (SBS)-toughened polylactide (PLA) blends. Upon compatibilization, the blends exhibited a refined dispersed-phase morphology, a decreased crystallinity with an increase in their amorphous interphase, improved thermal stability possibly from the thicker, stronger interfaces insusceptible to thermal energy, a convergence of the maximum decomposition-rate temperatures, enhanced magnitude of complex viscosity, dynamic storage and loss moduli, a reduced ramification degree in the high-frequency terminal region of the Han plot, and an increased semicircle radius in the Cole–Cole plot due to the prolonged chain segmental relaxation times from increases in the thickness and chain entanglement degree of the interphase. When increasing the S-MA content from 0 to 3.0 wt %, the tensile properties of the blends improved considerably until 1.0 wt %, above which they then increased insignificantly, whereas the impact strength was maximized at an optimum S-MA content of ~1.0 wt %, hypothetically due to balanced effects of the medium-size SBS particles on the stabilization of preexisting crazes and the initiation of new crazes in the PLA matrix. These observations confirm that S-MA, a random copolymer first synthesized in our laboratory, acted as an effective compatibilizer for the PLA/SBS blends.

3D Numerical Simulation of Reactive Extrusion Processes for Preparing PP/TiO₂ Nanocomposites in a Corotating Twin Screw Extruder

To better understand the relationship between flow, mixing and reactions in the process of preparing PP/TiO₂, a 3D numerical simulation in a co-rotating twin screw extruder (TSE) was firstly employed using commercial CFD code, ANSYS Polyflow. The effects of rotating speed of screws, stagger angle of knead blocks, inlet flow rate and initial temperature of barrel on the mixing and reaction process in the TSE were investigated. The results reveal that the studied operational and geometric parameters, which determine mixing efficiency, residence time distribution, and temperature of the flows in the TSE, affect the local species concentration, reaction time and reaction rate, and hence have great influences on the conversion rate. The results show that increasing the rotating speed and inlet flow rate can decrease the time for sufficient mixing, which is not conducive to intensive reaction, and increasing the stagger angle has the opposite effect. Moreover, the conversion rate greatly affected by the initial temperature of barrel.

A Facile Fabrication of High Toughness Poly(lactic Acid) via Reactive Extrusion with Poly(butylene Succinate) and Ethylene-Methyl Acrylate-Glycidyl Methacrylate

As is an excellent bio-based polymer material, poly(lactic acid) (PLA)'s brittle nature greatly restricts its extensive applications. Herein, poly(butylene succinate) (PBS) was introduced to toughening PLA by melt blending using a self-made triple screw extruder through in situ reactive with ethylene-methyl acrylate-glycidyl methacrylate (EGMA). The effect of EGMA concentrations on the mechanical properties, morphology, interfacial compatibility of PLA/PBS blends were studied. Fourier transform infrared (FT-IR) results demonstrated that the epoxy group of EGMA reacts with the hydroxyl groups of PLA and PBS, which proved the occurrence of interfacial reactions among the tri-component. The significantly improved compatibility between PLA and PBS after EGMA incorporation was made evident by scanning electron microscope (SEM) characterization results. Meanwhile, the contact angle test predicted that the EGMA was selectively localized at the interface between PLA and PBS, and the result was verified by morphological analysis of cryofracture and etched samples. The EGMA improves the compatibility of PLA/PBS blends, and consequently leads to a significantly increased toughness with the elongation at break occurring 83 times more when 10 wt % EGMA was introduced than neat PLA, while impact strength also enhanced by twentyfold. Ultimately, the toughening mechanism of PLA based polymers was established based on the above analysis, exploring a new way for the extensive application for degradable material.