Role of high-density polyethylene in the crystallization behaviors, rheological property, and supercritical CO2 foaming of poly (lactic acid)

Lightweight and High Impact Toughness PP/PET/POE Composite Foams Fabricated by In Situ Nanofibrillation and Microcellular Injection Molding

Polypropylene (PP) has become the most promising and candidate material for fabricating lightweight products. Microcellular injection molding (MIM) is a cost-effective technology for manufacturing porous plastic products. However, it is still challenging to fabricate high-performance PP microcellular components. Herein, we reported an efficient strategy to produce lightweight and high impact toughness foamed PP/polyethylene terephthalate (PET)/polyolefin-based elastomer (POE) components by combining in situ fibrillation (INF) and MIM technologies. First, the INF composite was prepared by integrating twin-screw compounding with melt spinning. SEM analysis showed PET nanofibrils with a diameter of 258 nm were achieved and distributed uniformly in the PP due to the POE's inducing elaboration effect. Rheological and DSC analysis demonstrated PET nanofibrils pronouncedly improved PP's viscoelasticity and crystal nucleation rate, respectively. Compared with PP foam, INF composite foam showed more stretched cells in the skin layer and refined spherical cells in the core layer. Due to the synergistic toughening effect of PET nanofibrils and POE elastic particles, the impact strength of INF composite foams was 295.3% higher than that of PP foam and 191.2% higher than that of melt-blended PP/PET foam. The results gathered in this study reveal potential applications for PP based INF composite foams in the manufacturing of lightweight automotive products with enhanced impact properties.

Dynamic Behavior of Thermally Affected Injection-Molded High-Density Polyethylene Parts Modified by Accelerated Electrons

Polyethylenes are the most widely used polymers and are gaining more and more interest due to their easy processability, relatively good mechanical properties and excellent chemical resistance. The disadvantage is their low temperature stability, which excludes particular high-density polyethylenes (HDPEs) for use in engineering applications where the temperature exceeds 100 °C for a long time. One of the possibilities of improving the temperature stability of HDPE is a modification by accelerated electrons when HDPE is cross-linked by this process and it is no longer possible to process it like a classic thermoplastic, e.g., by injection technology. The HDPE modified in this way was thermally stressed five times at temperatures of 110 and 160 °C, and then the dynamic tensile behavior was determined. The deformation and surface temperature of the specimens were recorded by a high-speed infrared camera. Furthermore, two thermal methods of specimen evaluation were used: differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The result of the measurement is that the modification of HDPE by accelerated electrons had a positive effect on the dynamic tensile behavior of these materials.

Polylactic Acid Chemical Foaming Assisted by Solid-State Processing: Solid-State Shear Pulverization and Cryogenic Milling

A chemical foaming process of polylactic acid (PLA) was developed via the solid-state processing methods of solid-state shear pulverization (SSSP) and cryogenic milling. Based on the ability of solid-state processing to enhance the crystallization kinetics of PLA, chemical foaming agents (CFA) are first compounded before foaming via compression molding. Specifically, the effects of the pre-foaming solid-state processing method and CFA concentration were investigated. Density reduction, mechanical properties, thermal behavior, and cell density of PLA foams are characterized. Solid-state processing of PLA before foaming greatly increases the extent of PLA foaming by achieving void fractions approximately twice that of the control foams. PLA's improved ability to crystallize is displayed through both dynamic mechanical analysis and differential scanning calorimetry. The solid-state-processed foams display superior mechanical robustness and undergo low stress relaxation. The cell density of the PLA foams also increases with solid-state processing, especially through SSSP. Additionally, crosslinking of PLA during the pre-foaming processing step is found to result in the greatest enhancement of crystallization but decreased void fraction and foam effectiveness. Overall, SSSP and cryogenic milling show significant promise in improving chemical foaming in alternative biopolymers.

Strategies and techniques for improving heat resistance and mechanical performances of poly(lactic acid) (PLA) biodegradable materials

Poly(lactic acid) (PLA) has attracted much attention as a substitute for petroleum-based plastics, but its low heat resistance limits its application range in packaging fields and disposable products. This paper summarizes the structural factors affecting the heat resistance of PLA and systematically summarizes methods to improve its heat resistance. PLA is a semi-crystalline polymer, and crystallinity, crystal size, and other factors are important factors affecting heat resistance. This paper systematically analyzes the means to control the crystallization behavior of PLA, and summarizes the effects of nucleating agents, cross-linking, grafting, and annealing processes on the crystallization behavior and heat resistance of PLA. The effects of PLA molecular chain cross-linking and grafting on the motility of PLA molecular chains and the heat resistance of PLA materials are further discussed from the perspective of PLA molecular chain segment movement. The research work on combining PLA with reinforcements such as high heat-resistant polymer materials, fiber, and nanoparticles to improve the mechanical properties and heat resistance of PLA by introducing rigid groups or structures is described in detail. Improving the heat resistance of PLA material is an important strategy to promote the application of biodegradable materials, and has broad research value and application prospects.

Effect of Temperature Ageing on Injection Molded High-Density Polyethylene Parts Modified by Accelerated Electrons

The temperature ageing of high-density polyethylene (HDPE) modified by accelerated electrons was studied. Commodity plastic HDPE was used as a basic polymer material which was modified by radiation cross-linking. This polymer was used because of its excellent processability and chemical resistance. Plastic injection molding technology was used for the production of test specimens. These specimens were modified with the dose of radiation 33, 66, 99, 132, 165, and 198 kGy. The prepared specimens were tested to determine: gel content, degree of swelling, temperature stability, and changes in mechanical properties after temperature ageing. The results were determined by scanning electron microscopy (SEM) analysis on the fracture surfaces. The results of this study confirm that modification of HDPE by radiation cross-linking has a significant effect on increasing temperature stability. It has been shown that HDPE modified by radiation cross-linking can withstand temperatures exceeding the melting point of the original HDPE for a short-term.

Crystallization, Structure and Significantly Improved Mechanical Properties of PLA/PPC Blends Compatibilized with PLA-PPC Copolymers Produced by Reactions Initiated with TBT or TDI

Poly (lactic acid) (PLA)-Poly (propylene carbonate) (PPC) block copolymer compatibilizers are produced in incompatible 70wt%PLA/PPC blend by initiating transesterification with addition of 1% of tetra butyl titanate (TBT) or by chain extension with addition of 2% of 2,4-toluene diisocyanate (TDI). The above blends can have much better mechanical properties than the blend without TBT and TDI. The elongation at break is dramatically larger (114% with 2% of TDI and 60% with 1% of TBT) than the blend without TDI and TBT, with a slightly lower mechanical strength. A small fraction of the copolymer is likely formed in the PLA/PPC blend with addition of TBT, and a significant amount of the copolymer can be made with addition of TDI. The copolymer produced with TDI has PPC as a major content (~70 wt%) and forms a miscible interphase with its own Tg. The crystallinity of the blend with TDI is significantly lower than the blend without TDI, as the PLA blocks of the copolymer in the interphase is hardly to crystallize. The average molecular weight increases significantly with addition of TDI, likely compensating the lower mechanical strength due to lower crystallinity. Material degradation can occur with addition of TBT, but it is very limited with 1% of TBT. However, compared with the blends without TBT, the PLA crystallinity of the blend with 1%TBT increases sharply during the cooling process, which likely compensates the loss of mechanical strength due to the slightly material degradation. The added TDI does not have any significant impact on PLA lamellar packing, but the addition of TBT can make PLA lamellar packing much less ordered, presumably resulted from much smaller PPC domains formed in the blend due to better compatibility.

Compatibilization and Characterization of Polylactide and Biopolyethylene Binary Blends by Non-Reactive and Reactive Compatibilization Approaches

In this study, different compatibilizing agents were used to analyze their influence on immiscible blends of polylactide (PLA) and biobased high-density polyethylene (bioPE) 80/20 (wt/wt). The compatibilizing agents used were polyethylene vinyl acetate (EVA) with a content of 33% of vinyl acetate, polyvinyl alcohol (PVA), and dicumyl peroxide (DPC). The influence of each compatibilizing agent on the mechanical, thermal, and microstructural properties of the PLA-bioPE blend was studied using different microscopic techniques (i.e., field emission electron microscopy (FESEM), transmission electron microscopy (TEM), and atomic force microscopy with PeakForce quantitative nanomechanical mapping (AFM-QNM)). Compatibilized PLA-bioPE blends showed an improvement in the ductile properties, with EVA being the compatibilizer that provided the highest elongation at break and the highest impact-absorbed energy (Charpy test). In addition, it was observed by means of the different microscopic techniques that the typical droplet-like structure is maintained, but the use of compatibilizers decreases the dimensions of the dispersed droplets, leading to improved interfacial adhesion, being more pronounced in the case of the EVA compatibilizer. Furthermore, the incorporation of the compatibilizers caused a very marked decrease in the crystallinity of the immiscible PLA-bioPE blend.

Preparation of high-strength and lightweight microcellular polysulfone foam with a segregated CNT network for excellent electromagnetic shielding

Fabrication of microcellular polymer composite foam based on high-performance plastic is a promising strategy for preparing the lightweight, high-strength and multifunctional materials. Herein, we proposed a facile and green method to prepare microcellular polysulfone/carbon nanotube (PSU/CNTs) composite foams with segregated structure by combining solid-phase milling and supercritical carbon dioxide (scCO₂) foaming. The segregated PSU/CNTs foam with as low as 5.0 wt% CNT was provided with a good electrical conductivity of 5.2 S m^-1 and an acceptable electromagnetic interference shielding effectiveness (EMI SE) of 23.7 dB, respectively. Moreover, the segregated PSU/CNT foam exhibited an ultralow percolation threshold of 0.06 vol%. An absorption-dominant shielding feature was observed for segregated PSU/CNT foam, which could be attributed to the synergistic effect of the perfect CNT networks and the microcellular structure in PSU domains. In addition, benefitting from the inherent properties of the PSU matrix, foam density dropped to 0.69 g cm^-3, and the material still possessed a high specific compression strength of 38.8 MPa cm³ g^-1. Therefore, our work provided an insight into the preparation of lightweight, high-strength and multifunctional materials that might have great potential applications in aerospace and military areas.

Morphological evaluation of ultralow density microcellular foamed composites developed through CO2-induced solid-state batch foaming technique utilizing water as co-blowing agent

In this work, microcellular acrylonitrile-butadiene-styrene foams were developed with utilization of water as a co-blowing agent and CO2 as the primary blowing agent through the solid-state batch foaming process. The effect of saturation parameters with the content of the co-blowing agent has been studied extensively for various foaming attributes. The co-blowing agent enhanced the average cell size and the expansion ratio which are useful for better thermal insulation. The maximum expansion ratio of 29.9 obtained from the effect of saturation temperature and co-blowing agent, 23.6 from the effect of saturation pressure and co-blowing agent, and 22.4 from the effect of saturation time and co-blowing agent. The co-blowing agent significantly affects the cell morphology of polymeric foam with saturation parameters.

Microcellular morphology evolution of polystyrene/thermoplastic polyurethane blends in the presence of supercritical CO2

In this article, a facile melt blending and solid batch foaming approach was proposed to prepare microcellular polystyrene/thermoplastic polyurethane (PS/TPU) blending foams with supercritical carbon dioxide (CO2). Compared with those of pure PS and pure TPU, an interesting phenomenon about the enhanced complex viscosity and storage modulus, as well as decreased loss factor of PS/TPU blends, was found. The solubility of CO2 in the PS/TPU blends was enhanced, owing to the CO2 solubilization effects of TPU. An interesting bimodal cell structure (BCS) was observed in the PS/TPU blending foams with the TPU content of 10, 15, and 20%. Consequently, a significant conclusion could be speculated that the generation of BCS in the PS/TPU blending system depended on not only the viscosity and morphology of the polymer blends but also the solubility and diffusivity of the CO2 as well as the type of cell nucleation. The thermal insulation property of PS foam was improved by the introduction of TPU.

Poly (lactic acid) blends: Processing, properties and applications

Poly (lactic acid) or polylactide (PLA) is a commercial biobased, biodegradable, biocompatible, compostable and non-toxic polymer that has competitive material and processing costs and desirable mechanical properties. Thereby, it can be considered favorably for biomedical applications and as the most promising substitute for petroleum-based polymers in a wide range of commodity and engineering applications. However, PLA has some significant shortcomings such as low melt strength, slow crystallization rate, poor processability, high brittleness, low toughness, and low service temperature, which limit its applications. To overcome these limitations, blending PLA with other polymers is an inexpensive approach that could also tailor the final properties of PLA-based products. During the last two decades, researchers investigated the synthesis, processing, properties, and development of various PLA-based blend systems including miscible blends of poly l-lactide (PLLA) and poly d-lactide (PDLA), which generate stereocomplex crystals, binary immiscible/miscible blends of PLA with other thermoplastics, multifunctional ternary blends using a third polymer or fillers such as nanoparticles, as well as PLA-based blend foam systems. This article reviews all these investigations and compares the syntheses/processing-morphology-properties interrelationships in PLA-based blends developed so far for various applications.

Multiple actions of poly(ethylene octene) grafted with glycidyl methacrylate on the performance of poly(lactic acid)

Poly(ethylene octene) grafted with glycidyl methacrylate (POE-g-GMA) was employed to improve the rheological and thermal properties, toughness, and foaming behaviors of poly(lactic acid) (PLA) through a chain extension effect.