Micro- and nano-layered processing of new polymeric systems

Improved Optimization of a Coextrusion Die with a Complex Geometry Using the Coupling Inverse Design Method

The main challenge in a polymer coextrusion process is to have a good die design prior to the process, which can minimize the geometric errors that are caused by extrusion swell and interface motion. For this purpose, a coupling method of optimization and inverse design for a coextrusion die was studied for a medical striped catheter. In the study, the main material was thermoplastic polyurethane (TPU), and the auxiliary material was TPU filled with 30 wt% barium sulfate. An overall optimization design method was used to optimize the geometry of the extrusion die channel for the striped catheter, which had a complex geometry. In the global optimization process, the local inverse design method was used to design the inlet of the auxiliary material. The non-linear programming by quadratic Lagrangian (NLPQL) algorithm was used to obtain the optimal geometric solution of the coextrusion die runner. The experimental verification results showed that the coupling method for coextrusion die design improved the design efficiency of the coextrusion die remarkably. The value of the objective function, which was used to measure the geometric error of the product, was reduced by 72.3% compared with the initial die design.

Toward Excellent Energy Storage Performance via Well-Aligned and Isolated Interfaces in Multicomponent Polypropylene-Based All-Organic Polymer Dielectric Films

Polypropylene (PP) serves as an excellent commercialized polymer dielectric film owing to its high breakdown strength, excellent self-healing ability, and flexibility. However, its low dielectric constant causes the large volume of the capacitor. Constructing multicomponent polypropylene-based all-organic polymer dielectric films is a facile strategy for achieving high energy density and efficiency simultaneously. Thereinto, the interfaces between the components become the key factors that determine the energy storage performance of the dielectric films. In this work, we propose to fabricate high-performance polyamide 513 (PA513)/PP all-organic polymer dielectric films via the construction of abundant well-aligned and isolated nanofibrillar interfaces. Laudably, a significant enhancement in the breakdown strength is achieved from 573.1 MV/m of pure PP to 692.3 MV/m with 5 wt % of PA513 nanofibrils. Besides, a maximum discharge energy density of about 4.4 J/cm² is realized with 20 wt % of PA513 nanofibrils, which is about 1.6-folds higher than pure PP. Simultaneously, the energy efficiency of samples with modulated interfaces maintains higher than 80% up to 600 MV/m, which is much higher than pure PP of about 40.7% at 550 MV/m. This work provides a new strategy to fabricate high-performance multicomponent all-organic polymer dielectric films on an industrial scale.

Overview of the Cast Polyolefin Film Extrusion Technology for Multi-Layer Packaging Applications

The review article presents the technology of producing polyolefin-based films by extrusion casting. Due to the wide use of this type of film as packaging for food and other goods, obtaining films with favorable properties is still a challenge for many groups of producers in the plastics market. The feedblock process and multimanifold process are the main methods of producing multi-layer film. In the case of food films, appropriate barrier properties are required, as well as durability and puncture resistance also at low temperatures. On the other hand, in order to properly pack and present products, an appropriate degree of transparency must be maintained. Therefore, processing aids such as anti-slip, anti-block and release agents are commonly used. Other popular modifiers, such as waxes, fatty acid amides and mineral fillers-silica, talc or calcium carbonate-and their use in film extrusion are discussed. The article also presents common production problems and their prevention.

A Journey from Processing to Recycling of Multilayer Waste Films: A Review of Main Challenges and Prospects

In a circular economy context with the dual problems of depletion of natural resources and the environmental impact of a growing volume of wastes, it is of great importance to focus on the recycling process of multilayered plastic films. This review is dedicated first to the general concepts and summary of plastic waste management in general, making emphasis on the multilayer films recycling process. Then, in the second part, the focus is dealing with multilayer films manufacturing process, including the most common materials used for agricultural applications, their processing, and the challenges of their recycling, recyclability, and reuse. Hitherto, some prospects are discussed from eco-design to mechanical or chemical recycling approaches.

Structuring Hydrogel Cross-Link Density Using Hierarchical Filament 3D Printing

Polymer hydrogels, water-laden 3D cross-linked networks, find broad application as advanced biomaterials and functional materials because of their biocompatibility, stimuli responsiveness, and affordability. The cross-linking density reports material properties such as elasticity, permeability, and swelling propensity. However, this critical design parameter can be challenging to template locally. Here, we report a continuous processing scheme that uses laminar flow to direct the organization of cross-linking density across a single sample. Dilute and concentrated poly(ethylene glycol) diacrylate solutions are fed into custom serpentine millifluidic devices. These feature a modular sequence of splitting, rotation, and recombination elements, which create patterned streamlines that serve as a template for hierarchical concentration distributions. Poly(acrylic acid) microgels impart viscoplasticity, which stabilizes layered flow during multiplication and ensures reliable advection. The devices produce structured, seamless filaments, which are then arranged into objects using 3D printing, and photopolymerized to secure the heterogeneous distribution. The flow-encoded, multiscale architecture provides mechanical contrast, which is demonstratively exploited to program robust and reversible shape transformations, potentially useful in soft actuator and sensor applications. The unique structures achieved, and the geometrically dictated, chemistry-agnostic operating principles used to achieve them, provides a new means to engineer hydrogels to suit a variety of applications.

The Role of Structure in Polymer Rheology: Review

The review is devoted to the analysis of the current state of understanding relationships among the deformation-induced structure transformations, observed rheological properties, and the occurrence of non-linear effects for polymer liquids (melts, solutions, and composites). Three levels of non-linearity are the base for consideration. The first one concerns changes in the relaxation spectra of viscoelastic liquids, which are responsible for weak non-linear phenomena. The second one refers to the strong non-linearity corresponding to such changes in the structure of a medium that leads to the emergence of a new relaxation state of a matter. Finally, the third one describes the deformation-induced changes in the phase state and/or the occurring of bifurcations and instability in flow and reflects the thermodynamic non-linear behavior. From a structure point of view, a common cause of the non-linear effects is the orientation of macromolecules and changes in intermolecular interaction, while a dominant factor in describing fluid dynamics of polymer liquids is their elasticity. The modern understanding of thixotropic effects, yielding viscoplastic materials, deformation-induced phase transition, and the experimental observations, demonstrating direct correlations between the structure and rheology of polymer liquids, are the main objects for discussion. All these topics are reviewed and discussed mainly on the basis of the latest five-year publications.

"Toolbox" for the Processing of Functional Polymer Composites

The processing methods of functional polymer composites (FPCs) are systematically summarized in “Toolbox”. The relationship of processing method-structure-property is discussed and the selection and combination of tools in processing among different FPCs are analyzed. A promising prospect is provided regarding the design principle for high performance FPCs for further investigation.

ABSTRACT

Functional polymer composites (FPCs) have attracted increasing attention in recent decades due to their great potential in delivering a wide range of functionalities. These functionalities are largely determined by functional fillers and their network morphology in polymer matrix. In recent years, a large number of studies on morphology control and interfacial modification have been reported, where numerous preparation methods and exciting performance of FPCs have been reported. Despite the fact that these FPCs have many similarities because they are all consisting of functional inorganic fillers and polymer matrices, review on the overall progress of FPCs is still missing, and especially the overall processing strategy for these composites is urgently needed. Herein, a “Toolbox” for the processing of FPCs is proposed to summarize and analyze the overall processing strategies and corresponding morphology evolution for FPCs. From this perspective, the morphological control methods already utilized for various FPCs are systematically reviewed, so that guidelines or even predictions on the processing strategies of various FPCs as well as multi-functional polymer composites could be given. This review should be able to provide interesting insights for the field of FPCs and boost future intelligent design of various FPCs. [Image: see text]

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s40820-021-00774-5.

Hierarchical Design of Functional, Fibrous, and Microporous Polymer Monoliths for the Molecular Recognition of Diethylstilbestrol

This paper demonstrates the hierarchical design of functional, fibrous polymer monoliths. The monoliths are composed of conjugated microporous polymers that not only are embedded with heteroatoms but also feature fibrous yet compressible structures due to the in situ self-assembly process that occurs during the polymerization process. Therefore, the doped nitrogen atoms can allow the growth of zeolitic imidazolate framework (ZIF) nanocrystals, which causes the homogeneous encapsulation of individual fibers. The resulting hybrid monoliths exhibit enhanced physical properties as well as catalytic activity, allowing the formation of an additional coating layer via a thiol-epoxy reaction. The deliberate inclusion of template molecules during the reaction forms molecularly imprinted sites on the fibers to afford functional monoliths. As a proof of concept, the hierarchically designed materials are able to show effective recognition properties toward diethylstilbestrol, an endocrine disruptor, taking advantage of the binding sites that selectively capture the analyte molecules and the fibrous morphology that increases the accessibility of these binding sites. We envisage that the incorporation of various heteroatoms or nanocrystals will bring about the bespoke design of advanced monoliths with autonomous functions, leading to smart textile systems.

Nanoparticles functionalized ceramic membranes: fabrication, surface modification, and performance

Membrane technologies are used intensively for desalination and wastewater treatment. Water filtration using ceramic membranes exhibited high performance compared with polymeric membranes due to various properties such as high resistance to fouling, permeability, rejection rate, and chemical stability. Recently, the performance of nanocomposite ceramic membranes was improved due to the development in nanotechnology. This article focusses on the development of porous ceramic membranes and nanomaterial functionalized ceramic membranes for water filtration applications. At the beginning, various fabrication methods of ceramic membranes were described, and the effect of surface modification techniques on the membrane intrinsic properties was reviewed. Then, the performance of nanoparticles functionalized ceramic membranes was evaluated in terms of physicochemical properties, rejection rate, and water permeability. This work can help new entrants and established researchers to become familiar with the current challenges and developments of nanoparticle-incorporated ceramic membranes for water filtration applications.

Morphology-Mechanical Performance Relationship at the Micrometrical Level within Molded Polypropylene Obtained with Non-Symmetric Mold Temperature Conditioning

The control of the structural properties of a polymeric material at the micro and nano-metrical scale is strategic to obtaining parts with high performance, durability and free from sudden failures. The characteristic skin-core morphology of injection molded samples is intimately linked to the complex shear flow, pressure and temperature evolutions experienced by the polymer chains during processing. An accurate analysis of this morphology can allow for the assessment of the quality and confidence of the process. Non-symmetric mold temperature conditions are imposed to produce complex morphologies in polypropylene parts. Morphological and micromechanical characterizations of the samples are used to quantify the effects of the processing conditions on the part performance. Asymmetric distribution of temperatures determines asymmetric distribution of both morphology and mechanical properties. The inhomogeneity degree depends on the time that one side of the cavity experiences high temperatures. The spherulites, which cover the thickest of the parts obtained with high temperatures at one cavity side, show smaller values of elastic modulus than the fibrils. When the polymer molecules experience high temperatures for long periods, the solid-diffusion and the partial melting and recrystallization phenomena determine a better structuring of the molecules with a parallel increase of the elastic modulus.

Multi-Micro/Nanolayer Films Based on Polyolefins: New Approaches from Eco-Design to Recycling

This paper describes a future-oriented approach for the valorization of polyethylene-based multilayer films. The method involves going from eco-design to mechanical recycling of multilayer films via forced assembly coextrusion. The originality of this study consists in limiting the number of constituents, reducing/controlling the thickness of the layers and avoiding the use of tie layers. The ultimate goal is to improve the manufacturing of new products from recycled multilayer materials by simplifying their recyclability. Within this framework, new structures were developed with two polymer systems: polyethylene/polypropylene and polyethylene/polystyrene, with nominal micro- and nanometric thicknesses. Hitherto, the effect of the multi-micro/nanolayer architecture as well as initial morphological and mechanical properties was evaluated. Several recycling processes were investigated, including steps such as: (i) grinding; (ii) monolayer cast film extrusion; or (iii) injection molding with or without an intermediate blending step by twin-screw extrusion. Subsequently, the induced morphological and mechanical properties were investigated depending on the recycling systems and the relationships between the chosen recycling processes or strategies, and structure and property control of the recycled systems was established accordingly. Based on the results obtained, a proof of concept was demonstrated with the eco-design of multi-micro/nanolayer films as a very promising solution for the industrial issues that arise with the valorization of recycled materials.

Fibrous mesoporous polymer monoliths: macromolecular design and enhanced photocatalytic degradation of aromatic dyes

A bottom-up design provides polymer monoliths comprising two monomers that form mesoporous, compressible, random fiber networks, as in marine sponges.

Multiscale Structural Evolution and Its Relationship to Dielectric Properties of Micro-/Nano-Layer Coextruded PVDF-HFP/PC Films

An understanding of the structural evolution in micro-/nano-layer co-extrusion process is essential to fabricate high-performance multilayered products. Therefore, in this work, we reveal systematically the multiscale structural development, involving both the layer architecture and microstructure within layers of micro-/nano-layer coextruded polymer films, as well as its relationship to dielectric properties, based on poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP)/polycarbonate (PC) system. Interestingly, layer architecture and morphology show strong dependences on the nominal layer thicknesses. Particularly, with layer thickness reduced to nanometer scale, interfacial instabilities triggered by viscoelastic differences between components emerge with the creation of micro-droplets and micro-sheets. Films show an enhanced crystallization with the formation of two-dimensional (2D) spherulites in microlayer coextruded systems and the oriented in-plane lamellae in nanolayer coextruded counterparts, where layer breakup in the thinner layers further changes the crystallization behaviors. These macro- and microscopic structures, developed from the co-extrusion process, substantially influence the dielectric properties of coextruded films. Mechanism responsible for dielectric performance is further proposed by considering these effects of multiscale structure on the dipole switching and charge hopping in the multilayered structures. This work clearly demonstrates how the multiscale structural evolution during the micro-/nano-layer coextrusion process can control the dielectric properties of multilayered products.

Multilayer packaging: Advances in preparation techniques and emerging food applications

In recent years, with advantages of versatility, functionality, and convenience, multilayer food packaging has gained significant interest. As a single entity, multilayer packaging combines the benefits of each monolayer in terms of enhanced barrier properties, mechanical integrity, and functional properties. Of late, apart from conventional approaches such as coextrusion and lamination, concepts of nanotechnology have been used in the preparation of composite multilayer films with improved physical, chemical, and functional characteristics. Further, emerging techniques such as ultraviolet and cold plasma treatments have been used in manufacturing films with enhanced performance through surface modifications. This work provides an up-to-date review on advancements in the preparation of multilayer films for food packaging applications. This includes critical considerations in design, risk of interaction between the package and the food, mathematical modeling and simulation, potential for scale-up, and costs involved. The impact of in-package processing is also explained considering cases of nonthermal processing and advanced thermal processing. Importantly, challenges associated with degradability and recycling multilayer packages and associated implications on sustainability have been discussed.