In-situ visualization of PLA crystallization and crystal effects on foaming in extrusion

Forefront Research of Foaming Strategies on Biodegradable Polymers and Their Composites by Thermal or Melt-Based Processing Technologies: Advances and Perspectives

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.

Composites made of Ginkgo biloba fibers and polylactic acid exhibit non-isothermal crystallization kinetics

Polymer crystallization affects material microstructure and the final product quality, and the crystallization kinetics that govern this process are critical. In this study, alkali-treated Ginkgo biloba fibers (GFs) were melt blended with polylactic acid (PLA) to obtain GF/PLA blends. The non-isothermal crystallization kinetics of the GF/PLA composites were subsequently investigated using the Avrami, Jeziorny, Ozawa, and Liu-Mo methods, and the crystallization activation energies of the systems were calculated by Kissinger and Friedman models. The results showed that the GFs significantly promoted PLA crystallization, accelerated the crystallization rate, and shortened the crystallization time. The Avrami method showed some deviation from the linear relationship due to the effect of secondary crystallization, while the numeric value obtained by the Jeziorny method increased with the cooling rate. The Ozawa method could only be used in a very narrow range of temperatures, while the Liu-Mo method showed a more desirable fit. Crystallization activation energy calculations showed that the GFs promoted an increase in the crystallization capacity of the blend and a decrease in the effective potential barrier. This resulted in more selective biocomposites than pure PLA, offering greater applicability in domains including tissue engineering and 3D printing.

Enhanced Degradability, Mechanical Properties, and Flame Retardation of Poly(Lactic Acid) Composite with New Zealand Jade (Pounamu) Particles

Plastic pollution has become a global concern, demanding urgent attention and concerted efforts to mitigate its environmental impacts. Biodegradable plastics have emerged as a potential solution, offering the prospect of reduced harm through degradation over time. However, the lower mechanical strength and slower degradation process of biodegradable plastics have hindered their widespread adoption. In this study, we investigate the incorporation of New Zealand (NZ) jade (pounamu) particles into poly(lactic acid) (PLA) to enhance the performance of the resulting composite. We aim to improve mechanical strength, flame retardation, and degradability. The material properties and compatibility with 3D printing technology were examined through a series of characterization techniques, including X-ray diffraction, dispersive X-ray fluorescence spectrometry, scanning electron microscopy, energy-dispersive X-ray spectroscopy, thermogravimetric analysis, 3D printing, compression molding, pycnometry, rheometry, tensile tests, three-point bending, and flammability testing. Our findings demonstrate that the addition of NZ jade particles significantly affects the density, thermal stability, and mechanical properties of the composites. Compounding NZ jade shows two different changes in thermal stability. It reduces flammability suggesting potential flame-retardant properties, and it accelerates the thermal degradation process as observed from the thermogravimetric analysis and the inferred decrease in molecular weight through rheometry. Thus, the presence of jade particles can also have the potential to enhance biodegradation, although further research is needed to assess its impact. The mechanical properties differ between compression-molded and 3D-printed samples, with compression-molded composites exhibiting higher strength and stiffness. Increasing jade content in composites further enhances their mechanical performance. Th results of this study contribute to the development of sustainable solutions for plastic pollution, paving the way for innovative applications and a cleaner environment.

High-Expansion Open-Cell Polylactide Foams Prepared by Microcellular Foaming Based on Stereocomplexation Mechanism with Outstanding Oil-Water Separation

Biodegradable polylactic acid (PLA) foams with open-cell structures are good candidates for oil-water separation. However, the foaming of PLA with high-expansion and uniform cell morphology by the traditional supercritical carbon dioxide microcellular foaming method remains a big challenge due to its low melting strength. Herein, a green facile strategy for the fabrication of open-cell fully biodegradable PLA-based foams is proposed by introducing the unique stereocomplexation mechanism between PLLA and synthesized star-shaped PDLA for the first time. A series of star-shaped PDLA with eight arms (8-s-PDLA) was synthesized with different molecular weights and added into the PLLA as modifiers. PLLA/8-s-PDLA foams with open-cells structure and high expansion ratios were fabricated by microcellular foaming with green supercritical carbon dioxide. In detail, the influences of induced 8-s-PDLA on the crystallization behavior, rheological properties, cell morphology and consequential oil-water separation performance of PLA-based foam were investigated systemically. The addition of 8-s-PDLA induced the formation of SC-PLA, enhancing crystallization by acting as nucleation sites and improving the melting strength through acting as physical cross-linking points. The further microcellular foaming of PLLA/8-s-PDLA resulted in open-cell foams of high porosity and high expansion ratios. With an optimized foaming condition, the PLLA/8-s-PDLA-13K foam exhibited an average cell size of about 61.7 μm and expansion ratio of 24. Furthermore, due to the high porosity of the interconnected open cells, the high-absorption performance of the carbon tetrachloride was up to 37 g/g. This work provides a facile green fabrication strategy for the development of environmentally friendly PLA foams with stable open-cell structures and high expansion ratios for oil-water separation.

High-expansion-ratio PLLA/PDLA/HNT composite foams with good thermally insulating property and enhanced compression performance via supercritical CO2

It has been a great challenge to prepare high-expansion-ratio polylactide (PLA) foam with eminent thermal insulation and compression performance in packaging field. Herein, a naturally formed nanofiller halloysite nanotube (HNT) and stereocomplex (SC) crystallites were introduced into PLA with a supercritical CO₂ foaming method to improve foaming behavior and physical properties. The compressive performance and thermal insulation properties of the obtained poly(L-lactic acid) (PLLA)/poly(D-lactic acid) (PDLA)/HNT composite foams were successfully investigated. At a HNT content of 1 wt%, the PLLA/PDLA/HNT blend foam with an expansion ratio of 36.7 folds showed a thermal conductivity as low as 30.60 mW/(m·K). Meanwhile, the compressive modulus of PLLA/PDLA/HNT foam was 115% higher than that of PLLA/PDLA foam without HNT. Moreover, the crystallinity of PLLA/PDLA/HNT foam was dramatically improved after annealing, thus the results showed that compressive modulus of the annealed foam increased by as high as 72%, while it still maintained good heat insulation with the thermal conductivity of 32.63 mW/(m·K). This work provides a green method for the preparation of biodegradable PLA foams with admirable heat resistance and mechanical performance.

Mechanical Properties of Injection Molded PP/PET-Nanofibril Composites and Foams

The creation and application of PET nanofibrils for PP composite reinforcement were studied. PET nanofibrils were fibrillated within a PP matrix using a spunbond process and then injection molded to test for the end-use properties. The nanofibril reinforcement helped to provide higher tensile and flexural performance in solid (unfoamed) injection molded parts. With foam injection molding, the nanofibrils also helped to improve and refine the microcellular morphology, which led to improved performance. Easily and effectively increasing the strength of a polymeric composite is a goal for many research endeavors. By creating nanoscale fibrils within the matrix itself, effective bonding and dispersion have already been achieved, overcoming the common pitfalls of fiber reinforcement. As blends of PP and PET are drawn in a spunbond system, the PET domains are stretched into nanoscale fibrils. By adapting the spunbonded blends for use in injection molding, both solid and foamed nanocomposites are created. The injection molded nanocomposites achieved increased in both tensile and flexural strength. The solid and foamed tensile strength increased by 50 and 100%, respectively. In addition, both the solid and foamed flexural strength increased by 100%. These increases in strength are attributed to effective PET nanofibril reinforcement.

Controlling stereocomplex crystal morphology in poly(lactide) through chain alignment

The incorporation of poly(d-lactide) (PDLA) to form stereocomplex crystallites (SCs) within a poly(l-lactide) (PLLA) matrix is among the most effective strategies in overcoming PLLA's numerous drawbacks. However, high concentrations of PDLA (>3 wt%) are required to improve PLLA's crystallization kinetics and melt strength, which is undesirable owing to PDLA's high cost. In this study, we use chain alignment as a levier to tune stereocomplex superstructure morphology to overcome these limitations. Herein, PLLA/PDLA blends were manufactured using an environmentally friendly and low-cost single step spunbond fibrillation process, yielding microfibers stretched to diameters of 5-20 μm. During this stretching process, PLLA and PDLA chains are aligned along the flow direction. SCs subsequently formed in situ upon heating, dramatically improving crystallization kinetics, melt elasticity, and tensile performance compared with neat PLLA and non-stretched blend analogues, even with low PDLA content (<3 wt%). These improvements were attributed to topological variations in SC superstructures caused by alignment of PLLA and PDLA chains. The application of chain alignment in tuning SC superstructure morphology is ubiquitous in fibrillation processes.

A facile strategy for preparation of strong tough poly(lactic acid) foam with a unique microfibrillated bimodal micro/nano cellular structure

This work reports the design and fabrication of strong tough poly(lactic acid) (PLA) foam by combining pressure-induced-flow (PIF) processing with supercritical CO₂ foaming. PIF processing widened the foaming window of PLA to 40-120 °C, while supercritical CO₂ foaming released the undesired internal stress of PLA samples with PIF processing (P-PLA). The prepared PLA foams displayed a unique microfibrillated bimodal micro/nano cellular structure which is strongly affected by saturation temperature (T_s). Both micron and nano cells showed decreasing cells size and increasing cell density as T_s elevated. The orientation factor as well as internal stress of PLA foams decreased with increased T_s. Compared with P-PLA samples, PLA foam prepared at T_s of 40 °C showed negligible reduction of orientation from 0.45 to 0.41 and release of internal stress characterized by the rightward shift of Raman peak (stretching vibration of CO bond from 1763 to 1766 cm^-1). Furthermore, PLA foam prepared at T_s of 40 °C presented excellent impact strength (32.3 kJ/m²), tensile strength (42.0 MPa), and ductility (14.2%). The combination of PIF processing and supercritical CO₂ foaming provides a facile and effective method to prepare strong tough PLA foam that has immense potential in biomedical, aerospace, automotive, and other structural applications.

Flexibly Controlling the Polycrystallinity and Improving the Foaming Behavior of Polylactic Acid via Three Strategies

Controlling foamability plays the central role in preparing PLA foams with high performances. To achieve this, chain extension was often used to improve the rheological property of PLA resins; however, despite the availability of this approach, it often deteriorates the biodegradability of PLA and greatly increases the processing cost and complexity. Hence, we reported a special crystallization induction method to design PLA foams with a tunable cellular structure and a high expansion ratio. A novel crystallization-promoting agent combination (D-sorbitol, CO2, and phenylphosphonic acid zinc salt) was used to induce PLA to enhance the chain interaction force and chain mobility and to provide crystallization templets. A series of PLAs with tunable stereocomplex (Sc)/α crystallinity and rapid non-isothermal crystallization ability were obtained. The effect of various crystallization properties on the foaming behavior of PLA was studied. The results demonstrated that proper crystallization conditions (a small spherulite size, a crystallinity of 6%, and rapid crystallization ability) could virtually contribute to the optimized cellular structure with the highest cell density of 4.36 × 106 cell/cm3. When the Sc crystallinity was above 10%, PLA had a superior foamability, which thereby resulted in a high foaming expansion ratio of 16.2. A variety of cellular morphologies of PLA foams could be obtained by changing the foaming temperature and the crystallization property. The proposed crystallization-induced approach provided a useful method for controlling the cellular structure and the performances of the PLA foams.

A green fabrication method of poly (lactic acid) perforated membrane via tuned crystallization and gas diffusion process

Poly (lactic acid) (PLA) perforated membrane is typically obtained through the solvent-volatilization-induced or non-solvent-induced phase separation (NIPS) method. However, the residual organic solvents would unavoidably limit the application of PLA perforated membrane in biomedical and high-end water purification fields. Herein, an innovative solution-free method was proposed for preparing the PLA perforated membrane via a simple and environmentally friendly way. We have successfully fabricated the PLA perforated membrane using a physical foaming technique with CO₂ as the blowing agent. By tuning the primary film thickness, saturation pressure, and foaming temperature, PLA perforated membrane's cell morphology could be accordingly adjusted. The PLA perforated membrane with a highly-ordered straight pore channel and high open cell content (OCC) approximately 72% was obtained under a mild condition. The formation mechanism of the PLA perforated membrane was discussed via the interaction of crystallization behavior and gas diffusion process. This green and solvent-free PLA perforated membrane possesses great potential for use in areas like the tissue engineering and high-end water purification.

Enhancing the accuracy and efficiency of characterizing polymeric cellular structures using 3D-based computed tomography

Characterizing the morphology of polymeric foams is crucial for determining their practical applicability. The internal cellular structure of polymeric foams is typically analyzed by 2 D imaging techniques, such as Scanning Electron Microscopy (SEM) and optical microscopy. The problem with these techniques is that their tests are tedious, destructive, and the accuracy of the obtained results is questionable. The objective of this paper is to establish and experimentally verify an efficient 3- dimensional (3 D) Microcomputed-tomography based methodology for reliably estimating and characterizing each of the phases commonly present in multiple types of polymeric foam samples, such as the open, the closed, and the solid phase. A comparative study was carried out between morphology data obtained from 2-dimensional (2 D) analysis and those obtained from 3 D analysis to investigate the reliability of the 2 D analysis results. In this context, the experimental results revealed that by using a 2 D method the open porosity was underestimated at the expense of closed porosity, which in turn was overestimated, while the total porosity was not impacted. Also, visualization of the internal structure of polymer foams by using Micro-CT provides details about the 3 D space which cannot be obtained from SEM images. The analysis of foamed specimen demonstrated that the polymeric foam phases extracted from Micro-CT images were in agreement with the experimentally measured values of total porosity of the samples. In an effort to reduce computational requirements, the effects of reducing data size on the accuracy of results has also been studied by averaging image pixels in 3 D space and the results were compared for multiple types of foam structures. This method reduced the processing time considerably, and yielded comparable porosity values. However, the number of detected pores were lowered due to the inability of this method to detect very small cells after 3 D averaging of image pixels.

Chemical Modification and Foam Processing of Polylactide (PLA)

Polylactide (PLA) is known as one of the most promising biopolymers as it is derived from renewable feedstock and can be biodegraded. During the last two decades, it moved more and more into the focus of scientific research and industrial use. It is even considered as a suitable replacement for standard petroleum-based polymers, such as polystyrene (PS), which can be found in a wide range of applications-amongst others in foams for packaging and insulation applications-but cause strong environmental issues. PLA has comparable mechanical properties to PS. However, the lack of melt strength is often referred to as a drawback for most foaming processes. One way to overcome this issue is the incorporation of chemical modifiers which can induce chain extension, branching, or cross-linking. As such, a wide variety of substances were studied in the literature. This work should give an overview of the most commonly used chemical modifiers and their effects on rheological, thermal, and foaming behavior. Therefore, this review article summarizes the research conducted on neat and chemically modified PLA foamed with the conventional foaming methods (i.e., batch foaming, foam extrusion, foam injection molding, and bead foaming).