Processing and characterization of solid and microcellular PHBV/coir fiber composites

Basic research on layered geopolymer composites with insulating materials of natural origin

New restrictions on carbon dioxide emissions and electricity consumption are currently being introduced around the world. Innovative solutions are being adopted in many countries to reduce CO2 emissions and material and energy consumption. The present work is related to the study of innovative binders based on geopolymers for the production of layered building envelopes. The binders are reinforced with composite bars and containing fibers of natural origin. The natural materials used to produce the samples are completely biodegradable. A 10-mol sodium hydroxide solution with an aqueous solution of sodium silicate was used for alkaline activation of geopolymers. The purpose of the study was to compare and determine the insulating properties of natural fiber-based materials such as coconut mat, jute felt, hemp felt, flax felt, flax wool, hemp wool, flax-jute wool, and to determine the effect of these materials on geopolymer composites, in which 4 layers of natural insulating materials were used, and the composites were reinforced by fiberglass bars. The publication presents the results of physicochemical studies of geopolymerization precursors and natural insulating materials, studies of thermal properties of fibers, mats, felts and wools, morphology of fiber structure and texture, as well as physical and thermal properties of finished multi-layer partitions. The results indicate the great potential of these materials in prefabrication and structural-insulation applications. The fabricated composites using 4 layers of natural fibers showed improved thermal conductivity by as much as 40% (reduced thermal conductivity from 1.36 W/m × K to about 0.8 W/m × K). The work may have future applications in energy-saving and low-carbon construction.

Influence of Coffee Variety and Processing on the Properties of Parchments as Functional Bioadditives for Biobased Poly(butylene succinate) Composites

Fermented polymers like biobased poly(butylene succinate) (BioPBS) have become more relevant as technical substitutes for ductile petrochemical-based polymers but require biogenic functional additives to deaccelerate undesired thermo-oxidative degradation and keep a fully biobased character. In this paper, the influence of coffee parchment (PMT) from two different varieties and processings on the thermo-oxidative stabilization and mechanical properties of poly(butylene succinate) composites up to 20 wt.-% PMT were investigated. Micronized with a TurboRotor mill, both PMT powders differ in particle size and shape, moisture ab- and adsorption behavior and antioxidative properties. It could be shown that pulped-natural PMT consists partially of coffee cherry residues, which leads to a higher total polyphenol content and water activity. The homogeneous PMT from fully washed processing has a higher thermal degradation resistance but consists of fibers with larger diameters. Compounded with the BioPBS and subsequent injection molded, the fully washed PMT leads to higher stiffness and equal tensile strength but lower toughness compared to the pulped-natural PMT, especially at lower deformation speed. Surprisingly, the fully washed PMT showed a higher stability against thermo-oxidative decomposition despite the lower values in the total phenol content and antioxidative activity. The required antioxidative stabilizers might be extracted at higher temperatures from the PMT fibers, making it a suitable biogenic stabilizer for extrusion processes.

Silane treated starch dispersed PBAT/PHBV-based composites: Improved barrier performance for single-use plastic alternatives

The objective of this study is to include 5 wt% silane-treated starch (S-t-Starch) into biodegradable flexible poly(butylene adipate-co-terephthalate) (PBAT)/poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) blend matrix, which can facilitate superior barrier and balanced mechanical properties. With the intension of improving compatibilization between matrix and filler, starch (biological macromolecule) was efficiently treated with 15 wt% of 3-glycidoxypropyl trimethoxy silane (GPTMS), a coupling agent. Various analyses such as barrier, mechanical, thermal, surface morphology and rheological were performed using cast extruded PBAT/PHBV-based composite films. Comprehensive characterizations suggested that cast extruded PBAT/PHBV with 5 wt% S-t-Starch composites exhibited 91 and 82 % improvement in oxygen and water vapor barrier, respectively, compared to PBAT film. The increment in % crystallinity (as supported by DSC analysis) of PBAT/PHBV/5%S-t-Starch composite due to the silane component was one of the reasons for barrier improvement. The other reason was the improved interfacial adhesion between matrix and S-t-Starch particles (as supported by SEM analysis), which restricted the mobility of the polymer chains. The elongation at break (%EB) of the cast extruded PBAT/PHBV/5%Starch film was slightly improved from 536 to 542 % after silane treatment. Hence, the developed polymer composite in this research work can contribute to flexible packaging applications that require improved barrier properties.

Alkaline Degradation of Plant Fiber Reinforcements in Geopolymer: A Review

Plant fibers (PFs), such as hemp, Coir, and straw, are abundant in resources, low in price, light weight, biodegradable, have good adhesion to the matrix, and have a broad prospect as reinforcements. However, the degradation of PFs in the alkaline matrix is one of the main factors that affects the durability of these composites. PFs have good compatibility with cement and the geopolymer matrix. They can induce gel growth of cement-based materials and have a good toughening effect. The water absorption of the hollow structure of the PF can accelerate the degradation of the fiber on the one hand and serve as the inner curing fiber for the continuous hydration of the base material on the other. PF is easily deteriorated in the alkaline matrix, which has a negative effect on composites. The classification and properties of PFs, the bonding mechanism of the interface between PF reinforcements and the matrix, the water absorption of PF, and its compatibility with the matrix were summarized. The degradation of PFs in the alkaline matrix and solution, drying and wetting cycle conditions, and high-temperature conditions were reviewed. Finally, some paths to improve the alkaline degradation of PF reinforcement in the alkaline matrix were proposed.

Novel insulation panels development from multilayered coir short and long fiber reinforced phenol formaldehyde polymeric biocomposites

This study investigated about the developments of insulation panels from multilayered coir long and short fiber reinforced phenol formaldehyde polymeric (PF) resin. The lengths of coir long fibers (CLF) were within 3 mm, whereas the short fibers (CSF) ranged from 0.1 mm to 1.25 mm. Four composite panels of 360, 680, 800, and 1000 kg/m3 densities were developed by employing hot pressing technology. The thermal conductivity, microstructural, mechanical, and physical properties of the composite panels were investigated. Perceived thermal conductivity values ranged within 0.046280 (0.000494) to 0.062400 (0.001146) Wm‒1 k‒1of the composites demonstrating superior insulation properties. Moreover, the current study also found that mechanical and thermal properties showed improvement with the increase of density. Low-density fiberboards had the lowest performances compared to high-density composite panels, with the exception of the 1000 kg/m3 density, in which fiber agglomeration occurred. Furthermore, all the developed composite panels display superior potentiality for use as effective insulation materials. The FTIR (Fourier transform infrared spectroscopy) analysis also shows an efficient bonding between the cellulosic coir materials and PF resin. The overall characteristics of the composite panels, especially medium fiberboard, show prominent potential for industrial production units by fulfilling the consumer requirements.

The Influence of Chosen Plant Fillers in PHBV Composites on the Processing Conditions, Mechanical Properties and Quality of Molded Pieces

This work is inspired by the current European policies that aim to reduce plastic waste. This is especially true of the packaging industry. The biocomposites developed in the work belong to the group of environmentally friendly plastics that can reduce the increasing costs of environmental fees in the future. Three types of short fibers (flax, hemp and wood) with a length of 1 mm each were selected as fillers (30% mass content in PHBV). The biocomposites were extruded and then processed by the injection molding process with the same technical parameters. The samples obtained in this way were tested for mechanical properties and quality of the molded pieces. A significant improvement of some mechanical properties of biocomposites containing hemp and flax fibers and quality of molded pieces was obtained in comparison with pure PHBV. Only in the case of wood–PHBV biocomposites was no significant improvement of properties obtained compared to biocomposites with other fillers used in this research. The use of natural fibers, in particular hemp fibers as a filler in the PHBV matrix, in most cases has a positive effect on improving the mechanical properties and quality of molded pieces. In addition, it should be remembered that the obtained biocomposites are of natural origin and are fully biodegradable, which are interesting and desirable properties that are a part of the current trend regarding the production and commercialization of modern biomaterials.

Influence of the Alkali Treatment of Flax and Hemp Fibers on the Properties of PHBV Based Biocomposites

This study assessed the impact of alkali treatment of hemp and flax fibers on mechanical properties (determined by means of the uniaxial tensile test, impact tensile strength test and hardness test), processing properties (the course of the extrusion and injection process) and usable properties (shrinkage of molded pieces, degree of water absorption) of biocomposites on the base of poly (3-hydroxybutyric-co-3-hydroxyvaleric acid) (PHBV) biopolymer. For this purpose, 1 mm of length flax and hemp fibers was surface-modified by means of aqueous solution of NaOH (sodium hydroxide) with concentrations of 2%, 5% and 10%. The composites were made using the extrusion technology. The test specimens were produced by injection molding technology. In total, eight types of biocomposites with modified and non-modified fibers were produced, and each biocomposite contained the same filler content (15 wt.%). Their properties were compared in some cases with pure PHBV polymer. In the case of biocomposites filled with hemp fibers, it was noted that an increase of the alkalizing solution concentration improved most of the tested properties of the obtained biocomposites. On the other hand, in the case of flax fibers, there was a significant decrease in most of the mechanical properties tested for the composite containing fibers etched by 10% NaOH solution. The obtained results were verified by examining fibers and the destroyed specimens with a scanning electron microscope (SEM) and an optical microscope, which confirmed, especially, the significant geometry changes of the flax fibers etched by 10% NaOH solution. This procedure also resulted in a significant change of processing properties—a composite of this fiber type required about 20 °C lower temperature during the extrusion and injection molding process in order to obtain the right product. These results lead to the important conclusion that for each filler of the plant-origin and polymer matrix, the fiber alkalization method should be selected individually in order to improve the specific properties of biocomposites.

A state-of-the-art review on coir fiber-reinforced biocomposites

The coconut (Cocos nucifera) fruits are extensively grown in tropical countries. The use of coconut husk-derived coir fiber-reinforced biocomposites is on the rise nowadays due to the constantly increasing demand for sustainable, renewable, biodegradable, and recyclable materials. Generally, the coconut husk and shells are disposed of as waste materials; however, they can be utilized as prominent raw materials for environment-friendly biocomposite production. Coir fibers are strong and stiff, which are prerequisites for coir fiber-reinforced biocomposite materials. However, as a bio-based material, the produced biocomposites have various performance characteristics because of the inhomogeneous coir material characteristics. Coir materials are reinforced with different thermoplastic, thermosetting, and cement-based materials to produce biocomposites. Coir fiber-reinforced composites provide superior mechanical, thermal, and physical properties, which make them outstanding materials as compared to synthetic fiber-reinforced composites. However, the mechanical performances of coconut fiber-reinforced composites could be enhanced by pretreating the surfaces of coir fiber. This review provides an overview of coir fiber and the associated composites along with their feasible fabrication methods and surface treatments in terms of their morphological, thermal, mechanical, and physical properties. Furthermore, this study facilitates the industrial production of coir fiber-reinforced biocomposites through the efficient utilization of coir husk-generated fibers.

RETRACTED ARTICLE: Property evaluations of coir fibres for use as reinforcement in composites

The density, tensile properties at different gauge lengths, Weibull modulus, and water absorption at elevated temperatures of coir fibres of Sri Lanka are presented. The tensile strength and stiffness of these fibres were found to decrease by 51.0 and 68.0% respectively as the gauge length of the coir fibres increased from 20 to 100 mm at a constant cross-head displacement rate of 1 mm/minute. The elongation at break of these fibres increased from 33.3 to 62.5% as the gauge length increased from 20 to 100 mm. The porosity of the fibres is in the range of 32.9–48.1% with an average pore count of 130–475 and average cell diameter of 6.8–13.7 µm within the studied diameter range of 0.162–0.313 mm. The porosity of coir fibres was found to increase as the diameter increased. TGA and scanning electron microscopy of failed samples were conducted to analyse the failure modes and to observe the trend in changes in the mechanical properties.

(Bio)Degradable Polymeric Materials for Sustainable Future-Part 3: Degradation Studies of the PHA/Wood Flour-Based Composites and Preliminary Tests of Antimicrobial Activity

The need for a cost reduction of the materials derived from (bio)degradable polymers forces research development into the formation of biocomposites with cheaper fillers. As additives can be made using the post-consumer wood, generated during wood products processing, re-use of recycled waste materials in the production of biocomposites can be an environmentally friendly way to minimalize and/or utilize the amount of the solid waste. Also, bioactive materials, which possess small amounts of antimicrobial additives belong to a very attractive packaging industry solution. This paper presents a study into the biodegradation, under laboratory composting conditions, of the composites that consist of poly[(R)-3-hydroxybutyrate-co-4-hydroxybutyrate)] and wood flour as a polymer matrix and natural filler, respectively. Thermogravimetric analysis, differential scanning calorimetry and scanning electron microscopy were used to evaluate the degradation progress of the obtained composites with different amounts of wood flour. The degradation products were characterized by multistage electrospray ionization mass spectrometry. Also, preliminary tests of the antimicrobial activity of selected materials with the addition of nisin were performed. The obtained results suggest that the different amount of filler has a significant influence on the degradation profile.

Natural Kenaf Fiber and LC3 Binder for Sustainable Fiber-Reinforced Cementitious Composite: A Review

Low impact on the environment and low cost are the key drivers for today’s technology uptake. There are many concerns for cement production in terms of negative environmental impact due to greenhouse gas (GHG) emission, deficiency of raw materials, as well as high energy consumption. Replacement of the cement by appropriate additives known as supplementary cementitious materials (SCMs) could result in reduction in GHG emission. Limestone-calcined clay cement (LC3) is a promising binder in the concrete sector for its improvements to environmental impact, durability, and mechanical properties. On the other hand, the advantages of fiber-reinforced concrete such as improved ductility, versatility, and durability have resulted in increasing demand for this type of concrete and introduction of new standards for considering the mechanical properties of fibers in structural design. Thus, using natural fibers instead of synthetic fibers can be another step toward the sustainability of the concrete industry, which is facing increasing demand for cement-based materials. This review studies the potential of natural Kenaf fiber-reinforced concrete containing LC3 binder as a step toward green cementitious composite. While studies show that energy consumption and GHG emission can be reduced and there is a significant potential to enhance mechanical and durability properties of concrete using this composition, adjustment of the mix design, assessing the long-term performance and standardization, are the next steps for the use of the material in practice.

Formulation and characterization of a novel PHBV nanocomposite for bone defect filling and infection treatment

Biodegradable materials that combine bioactivity with sustained drug release have been proved promising for the treatment and prophylaxis of bone infection. In this work, injection-molded nanocomposites were formulated from poly(3-hydroxybutyrate-co-3-6%hydroxyvalerate) (PHBV), nanodiamond (nD) and nanohydroxyapatite (nHA) loaded with vancomycin (VC). The components were compounded using a rotary evaporator (PHBV/nHA/VC/nD-R) or a spray-dryer (PHBV/nHA/VC/nD-SD). The nanoparticles acted as a nucleating agent, increasing PHBV crystallinity from 57.1% to up to 73.3% (PHBV/nHA/VC/nD-SD). The nHA particles were found to be well distributed on the formulations fracture surface observed by SEM-EDS micrographs. PHBV/nHA/VC/nD-SD presented higher glass transition temperature (18.1 vs 14.8 °C) and stronger interface than PHBV/nHA/VC/nD-R, as determined by dynamic mechanical analysis (DMA). Furthermore, the incorporation of nanoparticles increased PHBV flexural elastic modulus by 34% and match the reported for human bone. Both systems were able to present a sustained release of VC for 22 days, reaching 7.1 ± 1.3%(PHBV/nHA/VC/nD-R) and 4.8 ± 0.6% (PHBV/nHA/VC/nD-SD). VC presented antibacterial activity even after being processed at 178 °C in an injection molding machine. Moreover, in vitro assays showed a good adhesion and growth of cells on the specimens and suggested a non-cytotoxic and non-cytostatic behavior. These findings indicate that these systems can be further explored as bone defect filling material.

Unidirectional Rubber-Toughened Green Composites based on PHBV

The large-scale entry of bio-based polymers, such as poly(hydroxybutyrate-co-valerate) (PHBV), in applications commonly occupied by petroleum-based plastics is heavily limited by their poorer mechanical properties, thus, hindering efforts to reduce harmful plastic waste. Prior work to improve these properties has involved short natural fibre reinforcements, which do not produce substantial improvements. In this work, PHBV was simultaneously reinforced with unidirectional flax and toughened with poly(butylene adipate-co-terephthalate) (PBAT) or epoxidized natural rubber (ENR) to produce well-rounded composites. Toughened unidirectional composites were prepared by cryogenic grinding, powder layup and compression moulding. Unidirectional flax addition resulted in 4-fold increases in tensile properties, 3-fold increases in flexural properties and 20-fold increases in impact properties, whilst producing minimal change in the thermal properties. PBAT and ENR phases appeared well bonded to the PHBV within the composite. The addition of PBAT did not cause any significant changes in thermal or mechanical properties. The addition of ENR, however, reduced the tensile modulus and the flexural properties but produced a significant increase in impact strength, attributed to the coarse particle size of ENR. Unidirectional flax reinforcement of PHBV widens the scope of application of PHBV considerably where mechanical properties are of concern, while ENR has significant potential as a bio-based toughening agent for biocomposites.

Gas Dissolution Foaming as a Novel Approach for the Production of Lightweight Biocomposites of PHB/Natural Fibre Fabrics

The aim of this study is to propose and explore a novel approach for the production of cellular lightweight natural fibre, nonwoven, fabric-reinforced biocomposites by means of gas dissolution foaming from composite precursors of polyhydroxybutyrate-based matrix and flax fabric reinforcement. The main challenge is the development of a regular cellular structure in the polymeric matrix to reach a weight reduction while keeping a good fibre-matrix stress transfer and adhesion. The viability of the process is evaluated through the analysis of the cellular structure and morphology of the composites. The effect of matrix modification, nonwoven treatment, expansion temperature, and expansion pressure on the density and cellular structure of the cellular composites is evaluated. It was found that the nonwoven fabric plays a key role in the formation of a uniform cellular morphology, although limiting the maximum expansion ratio of the composites. Cellular composites with a significant reduction of weight (relative densities in the range 0.4⁻0.5) were successfully obtained.

Ultralight super-hydrophobic carbon aerogels based on cellulose nanofibers/poly(vinyl alcohol)/graphene oxide (CNFs/PVA/GO) for highly effective oil-water separation

With the worsening of the oil-product pollution problem, oil-water separation has attracted increased attention in recent years. In this study, a porous three-dimensional (3D) carbon aerogel based on cellulose nanofibers (CNFs), poly(vinyl alcohol) (PVA) and graphene oxide (GO) was synthesized by a facile and green approach. The resulting CNF/PVA/GO aerogels were synthesized through an environmentally friendly freeze-drying process and then carbonized to yield CNF/PVA/GO carbon aerogels with low density (18.41 mg cm^-3), high porosity (98.98%), a water contact angle of 156° (super-hydrophobic) and high oil absorption capacity (97 times its own weight). The carbonization treatment of the CNF/PVA/GO aerogel not only improved the hydrophobic properties but also enhanced the adsorption capacity and specific surface area. Given the many good performance characteristics and the facile preparation process of carbon aerogels, these materials are viable candidates for use in oil-water separation and environmental protection.

Fabrication of poly(ε-caprolactone) tissue engineering scaffolds with fibrillated and interconnected pores utilizing microcellular injection molding and polymer leaching

Three-dimensional fibrillated interconnected porous poly(ε-caprolactone) scaffolds were prepared by microcellular injection molding and polymer leaching.

Effects of surface modification and ultrasonic agitation on the properties of PHBV/ZnO nanocomposites

Zinc oxide (ZnO) particles were synthesized from aqueous solution by chemical precipitation method. Self-aggregated rod-shaped particles were obtained. Silane modification and ultrasonic dispersion were compared in terms of effectiveness on particle deagglomeration. Complete deagglomeration was achieved with ultrasonic dispersion for untreated particles. Surface-treated and/or ultrasound-applied ZnO particles were incorporated into PHBV matrix by melt-extrusion. Good particle dispersion was achieved in the composites regardless of the agglomeration observed in particles prior to polymer matrix inclusion. Number of regular, rod-shaped particles observed was higher in the composites produced with ultrasound-dispersed particles. ZnO crystals did not affect the melting and crystallization temperatures of PHBV composites, but the degree of crystallinity was decreased. Thermal degradation temperature of PHBV was slightly decreased with ZnO addition. Tensile strength, elongation at break, and toughness of PHBV were affected positively when ultrasound-dispersed (treated or untreated) particles were incorporated into PHBV matrix; whereas application of both ultrasound and silane treatment produced better results.

Modification and Potential Application of Short-Chain-Length Polyhydroxyalkanoate (SCL-PHA)

As the only kind of naturally-occurring biopolyester synthesized by various microorganisms, polyhydroxyalkanoate (PHA) shows a great market potential in packaging, fiber, biomedical, and other fields due to its biodegradablity, biocompatibility, and renewability. However, the inherent defects of scl-PHA with low 3HV or 4HB content, such as high stereoregularity, slow crystallization rate, and particularly the phenomena of formation of large-size spherulites and secondary crystallization, restrict the processing and stability of scl-PHA, as well as the application of its products. Many efforts have focused on the modification of scl-PHA to improve the mechanical properties and the applicability of obtained scl-PHA products. The modification of structure and property together with the potential applications of scl-PHA are covered in this review to give a comprehensive knowledge on the modification and processing of scl-PHA, including the effects of physical blending, chemical structure design, and processing conditions on the crystallization behaviors, thermal stability, and mechanical properties of scl-PHA.

Thermal, Morphological, and Biodegradability Properties of Bioplastic Fertilizer Composites Made of Oil Palm Biomass, Fertilizer, and Poly(hydroxybutyrate-co-valerate)

Slow-release bioplastic fertilizer (BpF) composites were developed by processing oil palm empty fruit bunch (EFB), fertilizer, and poly(hydroxybutyrate-co-valerate) (PHBv) using extrusion techniques with controlled formulation and temperature. The temperature was kept at 150°C for 3 to 5 min during processing using twin-screw extruder. The PHBv lost weight gradually with the increasing temperature and its thermal degradation occurred initially at 263.4°C and reached the maximum at 300.7°C. Scanning electron microscope (SEM) images showed that the bonding of all composites created small gaps between matrices polymer and fiber because the hydrophilic characteristic of EFB fibers weakened the interfacial bonding. PHBv/EFB/NPKC2 showed faster biodegradation over PHBv/NPKC1 and PHBv/NPKC2, which was 99.35% compared to 68.66% and 90.28%, respectively.

Poly(vinyl alcohol)/cellulose nanofibril hybrid aerogels with an aligned microtubular porous structure and their composites with polydimethylsiloxane

Superhydrophobic poly(vinyl alcohol) (PVA)/cellulose nanofibril (CNF) aerogels with a unidirectionally aligned microtubular porous structure were prepared using a unidirectional freeze-drying process, followed by the thermal chemical vapor deposition of methyltrichlorosilane. The silanized aerogels were characterized using various techniques including scanning electron microscopy (SEM), Fourier transform infrared spectroscopy, and contact angle measurements. The structure of the aerogels fully filled with polydimethylsiloxane (PDMS) was confirmed by SEM and optical microscopy. The mechanical properties of the resulting PDMS/aerogel composites were examined using both compressive and tensile tests. The compressive and tensile Young's moduli of the fully filled PDMS/aerogel composites were more than 2-fold and 15-fold higher than those of pure PDMS. This study provides a novel alternative approach for preparing high performance polymer nanocomposites with a bicontinuous structure.

Novel bio-based composites of polyhydroxyalkanoate (PHA)/distillers dried grains with solubles (DDGS)

SEM morphology and DSC measurements for bio-based PHA/DDGS composites of different compositions.

Mechanical properties and foaming behavior of injection molded cellulose fiber reinforced polypropylene composite foams

This paper investigates the effects of cellulose content and processing conditions on the mechanical properties and foaming behavior of injection molded cellulose fiber reinforced polypropylene composite foams. Composite foams were injection molded using an advanced structural foam molding machine with N2 as a physical blowing agent. Foamed specimens were prepared at different injection speeds and void fractions. The mechanical properties and foam morphologies of the specimens were evaluated. The results suggested that the specific flexural modulus was increased and the specific flexural strength and Izod impact strength were maintained by foaming, and that the strength, modulus, and notched Izod impact strength increased with the increase of cellulose content. Additionally, the results suggested that the cell morphology of the composite foams was improved by the increase of void fraction and the addition of cellulose fiber.