Poly(lactic acid)-Based in Situ Microfibrillar Composites with Enhanced Crystallization Kinetics, Mechanical Properties, Rheological Behavior, and Foaming Ability

Enhancing Mechanical Performance of High-Density Polyethylene at Different Environmental Conditions with Outstanding Foamability through In-Situ Rubber Nanofibrillation: Exploring the Impact of Interface Modification

In this study, we utilized in situ nanofibrillation of thermoplastic polyester ether elastomer (TPEE) within a high-density polyethylene (HDPE) matrix to enhance the rheological properties, foamability, and mechanical characteristics of the HDPE nanocomposite at both room and subzero temperatures. Due to the inherent polarity differences between these two components, TPEE is thermodynamically incompatible with the nonpolar HDPE. To address this compatibility issue, we employed a compatibilizer, styrene/ethylene-butylene/styrene copolymer-grafted maleic anhydride (SEBS-g-MA), to reduce the interfacial tension between the two blend components. In the initial step, we prepared a 10% masterbatch of HDPE/TPEE with and without the compatibilizer using a twin-screw extruder. Subsequently, we processed the 10% masterbatch further through spun bonding to create fiber-in-fiber composites. Scanning electron microscopy (SEM) analysis revealed a significant reduction in the spherical size of HDPE/TPEE particles following the inclusion of SEBS-g-MA, as well as a much smaller TPEE nanofiber size (approximately 60-70 nm for 5% TPEE). Moreover, extensional rheological testing revealed a notable enhancement in extensional rheological properties, with strain-hardening behavior being more pronounced in the compatibilized nanofibrillar composites compared to the noncompatibilized ones. SEM images of the foam structures depicted substantial improvement in the foamability of HDPE in terms of the cell size and density following the nanofibrillation process and the use of the compatibilizer. Ultimately, the in situ rubber fibrillation and enhancement of HDPE and TPEE interface using a compatibilizer led to increasing the HDPE ductility at room and subzero temperatures while maintaining its stiffness.

Preparation of tomato peel pomace powder/polylactic acid foams under supercritical CO2 conditions: Improvements in cell structure and foaming behavior

Polylactic acid (PLA) is an eco-friendly material that can help address the problems of petroleum depletion and pollution. Blending renewable biomass materials with PLA to create composite foams with a tunable pore structure, superior performance, and low cost is a green technique for improving the pore structure and mechanical characteristics of single PLA foams. PLA/TP composites were created using melted tomato peel pomace powder (TP), which has a lamellar structure, as a reinforcing agent. Then, the relationship between the vesicle structure, morphology, and properties of the PLA/TP composite foams produced through supercritical CO2 intermittent foaming were investigated. The findings revealed that TP considerably enhanced the rheological characteristics and crystalline behavior of PLA. The PLA/TP composite foam had a better cell structure, compression characteristics, and wettability than pure PLA. The expansion ratio of the PLA/TP composite could reach 18.8, and its thermal conductivity decreased from 174.2 mW/m·K at 100 °C to 57.8 mW/m·K at 120 °C. Furthermore, annealing before foaming decreased the average composite foam blister size from 110.09 to 66.53 μm, and the annealing process also improved compression performance. This study contributes to solving environmental difficulties and creating PLA foams with controlled bubble structures, uniform bubble sizes, and outstanding overall performance.

Biodegradable nanofibrillated microcellular PBS/PLA foams for selective oil absorption

To address the challenges posed by spilled oil and oily wastewater, the development of clean oil-adsorption materials is crucial. However, traditional oil-adsorption materials suffer from the issue of secondary pollution. Herein, fully biodegradable nanofibrillated poly(butylene succinate)/poly(lactic acid) (PBS/PLA) foams with outstanding selective oil-adsorption performance were successfully fabricated via an eco-friendly supercritical CO2 foaming technology. The PBS/PLA composites, featuring nanofibrils with a diameter of approximately 100 nm, were prepared through a hot-stretching method subsequent to extrusion. Substantial improvements were observed in the crystallization rate and rheological properties of the fibrillated PBS/PLA composites. Furthermore, PLA nanofibrils enhanced foamability of the composite, achieving an impressive expansion ratio of up to 38.0, resulting in an outstanding oil-absorption performance (19.2-50.4 g/g) of the F-1 %-95 foam. Additionally, 20 adsorption-desorption cycles illustrated the prepared F-1 %-95 foam displayed recyclable oil-absorption characteristics. This work provides an eco-friendly strategy for preparing fully biodegradable foams intended for application as oil-adsorption materials.

A Versatile Disorder-to-Order Technology to Upgrade Polymers into High-Performance Bioinspired Materials

Biodegradable polymer as traditional material has been widely used in the medical and tissue engineering fields, but there is a great limitation as to its inferior mechanical performance for repairing load-bearing tissues. Thus, it is highly desirable to develop a novel technology to fabricate high-performance biodegradable polymers. Herein, inspired by the bone's superstructure, a versatile disorder-to-order technology (VDOT) is proposed to manufacture a high-strength and high-elastic modulus stereo-composite self-reinforced polymer fiber. The mean tensile strength (336.1 MPa) and elastic modulus (4.1 GPa) of the self-reinforced polylactic acid (PLA) fiber are 5.2 and 2.1 times their counterparts of the traditional PLA fiber prepared by the existing spinning method. Moreover, the polymer fibers have the best ability of strength retention during degradation. Interestingly, the fiber tensile strength is even higher than those of bone (200 MPa) and some medical metals (e.g., Al and Mg). Based on all-polymeric raw materials, the VDOT endows bioinspired polymers with improved strength, elastic modulus, and degradation-controlled mechanical maintenance, making it a versatile update technology for the massive industrial production of high-performance biomedical polymers.

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.

Preparing low-Density microcellular polystyrene foam by in-Situ fibrillated PTFE and supramolecular nucleator TMC-300 in the presence of sc-CO2

A method using in-situ fibrillated polytetrafluoroethylene (PTFE) and octamethylenedicarboxylicdibenzoylhydrazide (TMC-300) supramolecular nucleator was presented to prepare low density polystyrene foams. This study used a torque rheometer in the molten compound preparation of PS/fibrillated-PTFE/TMC-300 composites. Scanning electron microscopy showed in-situ fibrillated polytetrafluoroethylene in Polystyrene melt and a nanofiber network with high aspect ratio. The formation of nanometer-sized fiber networks improved the melt viscoelasticity of matrices which promoted cell nucleation. As the results demonstrated, low-density foams with 11 μm average cell size were obtained using Polystyrene. The self-assembly nucleating agent TMC-300 was then introduced to the composite materials. TMC-300 and polytetrafluoroethylene as a composite cell nucleating agent were used in Polystyrene foams. Meanwhile, their nucleating efficiency was investigated. TMC-300 completed self-assembly in Polystyrene and served as composite nucleating agent in combination with polytetrafluoroethylene. Compared with the sample PS/PTFE-0.5, the average cell size of the sample PS/PTFE-0.5/TMC-2 had a reduction rate of 28.16% from 12.18 μm to 8.75 μm. The cell density increased by an order of magnitude. The composite nucleating agent was successful in controlling Polystyrene foam cell morphology, thus leading to the preparation of low-density Polystyrene microporous foams.

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.

Improvement of the Thermal Stability of Polymer Bioblends by Means of Reactive Extrusion

Poly(lactic acid) (PLA) and biosourced polyamide (PA) bioblends, with a variable PA weight content of 10-50%, were manufactured by melt blending in order to improve the behavior of PLA against thermal degradation. The effect of reactive extrusion on the thermal performance of PLA within bioblends was analyzed. The reactive extrusion was made by means of the addition of a styrene-acrylic multi-functional-epoxide oligomeric reactive agent (SAmfE), with the commercial name of Joncryl. Four parameters were considered in order to study the thermal behavior of bioblends against thermal decomposition: the onset decomposition temperature, the shape and temperature interval of the thermal decomposition patterns, the activation energy of the thermal decomposition, and the evidence leading to the most probable mechanism. The latter was determined by means of three evidence: standardized conversion functions, y(α) master plots, and integral mean error. It was shown that reactive extrusion of PLA as well as PA incorporation to the polymer matrix of PLA were responsible for an increase in the onset decomposition temperature of 10.4 °C. The general analytical equation (GAE) was used to evaluate the kinetic parameters of the thermal degradation of PLA within bioblends for various reaction mechanisms. It was shown that the random scission of macromolecular chains is the best mechanism for both untreated and treated PLA by means of reactive extrusion. It was shown that reactive extrusion together with higher content of PA resulted in an increased protective effect against the thermal degradation of PLA as demonstrated by an increase in activation energy of 60 kJ/mol. It was found that there is a relationship between the increase in activation energy and the increase in the onset decomposition temperature when using reactive extrusion. The improvement of the thermal stability of bioblends by means of reactive extrusion was explained by an increase in the complex viscosity from 980 to 2000 Pa·s at 0.06 rad/s and from 250 to 300 Pa·s at 630 rad/s for bioblend containing 30% of PLA_REX and by a finer dispersion of PA within the PLA_REX matrix. Results from DSC were not conclusive regarding the compatibility between both phases.

Morphology and Properties of Polyolefin Elastomer/Polyamide 6/Poly(lactic Acid) In Situ Special-Shaped Microfibrillar Composites: Influence of Viscosity Ratio

In Situ microfibrillation is an easy and economical processing method, which has drawn wide concern in recent years. In Situ special-shaped microfibrillar composites, which with poly(lactic acid)/polyamide 6 (PA6/PLA) together formed special-shaped microfibrils in polyolefin elastomer (POE) matrix, were successfully prepared by using multistage stretching extrusion technology. Four types of PA6 with different viscosity were utilized to investigate the effect of viscosity ratio of PA6 to PLA on the structure evolution of special-shaped microfibrils and the mechanical properties of POE/(PA6/PLA) composites. The morphological observation showed that the viscosity ratio was closely associated to the size and shape of PA6 and greatly affected the microfibrillar morphology of PLA/PA6. When the viscosity ratio of PA6 to PLA was less than 2.2, the “gourd-skewers-like” structure microfibrils were obtained. When the viscosity ratio of PA6/PLA to 14.2 was further increased, the “trepang” structure microfibrils were dominant. The “gourd skewers” structure microfibrils were favorable to improvement the tensile strength, Young’s modulus, and viscoelastic properties of POE/(PA6/PLA) blends compared to the “trepang” structure microfibrils. In addition, the morphology of microfibrils exhibited a negligible effect on the melting and crystallization temperature and crystallization degree of PLA and POE matrix. This work provides a new strategy for designing the in situ special-shaped microfibrillar composites with improved mechanical properties.

Vitrimeric Polylactide by Two-step Alcoholysis and Transesterification during Reactive Processing for Enhanced Melt Strength

Because of its rather low melt strength, polylactide (PLA) has yet to fulfill its promise as advanced biobased and biodegradable foams to replace fossil-based polymer foams. In this work, PLA vitrimers were prepared by two-step reactive processing from commercial PLA thermoplastics, glycerol, and diphenylmethane diisocyanate (MDI) using Zn(II)-catalyzed addition and transesterification chemistry. The transesterification reaction of PLA and glycerol occurs with zinc acetate as the catalyst, and chain scission will take place due to the alcoholysis of the PLA chains by the free hydroxyl groups from the glycerol. Long-chain PLA with hydroxyl groups can be obtained and then cross-linked with MDI. Rheological analysis shows that the formed cross-linked network can significantly improve melt strength and promote strain hardening under extensional flow. PLA vitrimers still maintain the ability of thermoplastic processing via extrusion and compression. The enhanced melt strength and the rearrangement of network topology facilitate the foaming processing. An expansion ratio as large as 49.2-fold and microcellular foam with a uniform cell morphology can be obtained for PLA vitrimers with a gel fraction of 51.8% through a supercritical carbon dioxide foaming technique. This work provides a new way with the scale-up possibility to enhance the melt strength of PLA, and the broadened range of PLA applicability brought by PLA vitrimers is truly valuable in terms of the realization of a sustainable society.

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.

Water-Induced Crystal Transition and Accelerated Relaxation Process of Polyamide 4 Chains in Microfibers

Microplastics have recently been identified as one of the major contributors to environmental pollution. To design and control the biodegradability of polymer materials, it is crucial to obtain a better understanding of the aggregation states and thermal molecular motion of polymer chains in aqueous environments. Here, we focus on melt-spun microfibers of a promising biodegradable plastic, polyamide 4 (PA4), with a relatively greater number density of hydrolyzable amide groups, which is regarded as an alternative to polyamide 6. Aggregation states and thermal molecular motion of PA4 microfibers without/with a post-heating drawing treatment under dry and wet conditions were examined by attenuated total reflectance-Fourier transform infrared spectroscopy and wide-angle X-ray diffraction analysis in conjunction with dynamic mechanical analysis. Sorbed water molecules in the microfibers induced the crystal transition from a meta-stable γ-form to a thermodynamically stable α-form via activation of the molecular motion of PA4 chains. Also, the post-drawing treatment caused a partial structural change of PA4 chains, from an amorphous phase to a crystalline phase. These findings should be useful for designing PA4-based structural materials applicable for use in marine environments.

Microporous Formation Mechanism of Biaxial Stretching PA6/PP Membranes with High Porosity and Uniform Pore Size Distribution

The low porosity and wide pore size distribution of biaxial stretching PP microporous membranes continue to be the primary impediments to their industrial application. To solve this problem, there is a critical and urgent need to study the micropore-forming mechanism of PP membranes. In this research, the interfacial micropore formation mechanism of PA6/PP membranes during biaxial stretching was investigated. PA6/PP membranes containing spherical PA6 and fibrillar PA6 were found to exhibit different interfacial micropore formation mechanisms. Numerous micropores were generated in the PA6/PP membranes, containing PA6 spherical particles via the interface separation between the PP matrix and PA6 spherical particles during longitudinal stretching. Subsequent transverse stretching further expanded the two-phase interface, promoting the breakdown and fibrosis of the PP matrix and forming a spider-web-like microporous structure centered on spherical PA6 particles. In PA6/PP membranes with PA6 fibers, fewer micropores were generated during longitudinal stretching, but the subsequent transverse stretching violently separated the PA6 fibers, resulting in a dense fiber network composed of PA6 fibers interwoven with PP fibers. Crucially, the PA6/PP biaxial stretching of microporous membranes presented an optimized pore structure, higher porosity, narrower pore size distribution, and better permeability than β-PP membranes. Furthermore, this study explored a new approach to the fabrication of high-performance PA6/PP microporous membranes, with good prospects for potential industrial application.

Generation of Tough, Stiff Polylactide Nanocomposites through the In Situ Nanofibrillation of Thermoplastic Elastomer

Polylactide (PLA) resins are among the most desirable biopolymers due to their biobased and compostable nature, excellent stiffness, and tensile strength. However, the widespread application of PLA has long been hindered by its inherent brittleness. While multiple routes have been successfully developed for the toughening of PLA, this toughening has always come at the cost of compromising the stiffness and strength of the matrix. In this work, we report a robust and scalable method for the development of PLA nanocomposites with an unprecedented combination of stiffness and toughness. Using the in situ nanofibrillation technique, we generated PLA composites containing nanofibrils of thermoplastic polyester elastomer (TPEE). Due to the high aspect ratio of these nanofibrils, they form physically percolated networks at low weight fractions (∼2.8 wt %) which dramatically change the mechanical behavior of the material. We found that, upon network formation, the material transitions from brittle to ductile behavior, dramatically increasing its toughness with only a marginal decrease in Young's modulus. We investigate the peculiar rheological behavior and crystallization kinetics of these blends, and propose an extension of the critical ligament thickness mechanism, wherein intrinsic toughening arises at the fiber-matrix interface in the presence of entangled elastomer networks.

Entirely environment-friendly polylactide composites with outstanding heat resistance and superior mechanical performance fabricated by spunbond technology: Exploring the role of nanofibrillated stereocomplex polylactide crystals

This study aims at investigating the manufacturing and characterization of all-polylactide composites prepared by melt spunbond spinning technology. To do so, a series of asymmetric stereocomplex polylactide (SC-PLA) blends (PLLA 95 wt%/PDLA 5 wt%) was melt spun. To examine the impact of molecular structure of PDLA, the blends of linear PLLA, and low and high molecular weight as well as branched PDLAs, were subjected to a single step spunbond process. DSC thermograms of the samples showed two melting temperatures at around 170 °C and 210 °C, which were attributed to the melting of homo and stereocomplex crystals, respectively. The samples were spun at 190 °C, between the homo and stereocomplex crystals' melting temperatures, and at 230 °C, above the stereocomplex crystals' melting temperature. Morphology images showed the formation of fibers in the range of 40-50 μm. Shear rheological measurements revealed that the spun SC-PLA samples had a substantially higher viscosity and storage modulus in the low frequency region, and higher shear thinning behavior, compared to the non-spun samples. Extensional rheology measurements also showed that the spun samples demonstrated strain hardening behavior. Substantial enhancement of rheological properties was noted for the samples containing the branched and high molecular weight PDLA spun at 230 °C. After etching, the spun samples at 190 °C exhibited small spherical crystals with diameters in the range of 80-90 nm, whereas comparatively thin fibers in the size range of 60-70 nm were observed for the samples spun at 230 °C. Remarkable enhancements up to 100% and 60% was noted for the tensile modulus and strength, respectively, of the spun SC-PLA samples. The spun fibers also demonstrated a considerable reduction in boiling water and hot air shrinkage. The distinctive role of nanofibrillated stereocomplex crystals as a rheology modifier and a crystallization nucleating agent makes PLA more sustainable and paves the way for the fabricated all-PLA composites in applications requiring high heat resistance and superior mechanical performance. The present study unequivocally indicates a huge potential for the sustainable entirely all-PLA products manufactured by fiber in fiber and, indeed, unfolds unknown opportunities for PLA-based merchandises in future.

Ultra-light poly(lactic acid)/SiO2 aerogel composite foam: A fully biodegradable and full life-cycle sustainable insulation material

In this study, a fully biodegradable ultra-light poly(lactic acid)/silicon dioxide (PLA/SiO₂) aerogel nanocomposite with ultra-low thermal conductivity was successfully fabricated. PLA used was a produced from lactic acid, where the lactic acid has been produced from carbohydrates. The rheological properties of PLA were enhanced by diphenylmethane diisocyanate (MDI). The foaming properties, cell density, cell size uniformity, mechanical properties and thermal conductivity and thermal diffusivity of PLA were further improved by SiO₂ aerogel, and finally the ultra-low density foamed material was prepared by supercritical CO₂. The density of PLA foam can be as low as 0.02 g/cm³ and the thermal conductivity as low as 0.02628 W/m·K. The PLA-based composites can be used in many fields such as thermal insulation, vibration damping and packaging, and can be fully biodegradable and sustainable throughout their life cycle, which meets the global trend of energy saving and emission reduction.

Kinetics of the Thermal Degradation of Poly(lactic acid) and Polyamide Bioblends

Poly(lactic acid) (PLA) and biosourced polyamide (PA) bioblends, with a variable PA weight content of 10–50%, were prepared by melt blending in order to overcome the high brittleness of PLA. During processing, the properties of the melt were stabilized and enhanced by the addition of a styrene-acrylic multi-functional-epoxide oligomeric reactive agent (SAmfE). The general analytical equation (GAE) was used to evaluate the kinetic parameters of the thermal degradation of PLA within bioblends. Various empirical and theoretical solid-state mechanisms were tested to find the best kinetic model. In order to study the effect of PA on the PLA matrix, only the first stage of the thermal degradation was taken into consideration in the kinetic analysis (α < 0.4). On the other hand, standardized conversion functions were evaluated. Given that it is not easy to visualize the best accordance between experimental and theoretical values of standardized conversion functions, an index, based on the integral mean error, was evaluated to quantitatively support our findings relative to the best reaction mechanism. It was demonstrated that the most probable mechanism for the thermal degradation of PLA is the random scission of macromolecular chains. Moreover, y(α) master plots, which are independent of activation energy values, were used to confirm that the selected reaction mechanism was the most adequate. Activation energy values were calculated as a function of PA content. Moreover, the onset thermal stability of PLA was also determined.

Effect of the Elongational Flow on the Morphology and Properties of Polymer Systems: A Brief Review

Polymer-processing operations with dominating elongational flow have a great relevance, especially in several relevant industrial applications. Film blowing, fiber spinning and foaming are some examples in which the polymer melt is subjected to elongational flow during processing. To gain a thorough knowledge of the material-processing behavior, the evaluation of the rheological properties of the polymers experiencing this kind of flow is fundamental. This paper reviews the main achievements regarding the processing-structure-properties relationships of polymer-based materials processed through different operations with dominating elongational flow. In particular, after a brief discussion on the theoretical features associated with the elongational flow and the differences with other flow regimes, the attention is focused on the rheological properties in elongation of the most industrially relevant polymers. Finally, the evolution of the morphology of homogeneous polymers, as well as of multiphase polymer-based systems, such as blends and micro- and nano-composites, subjected to the elongational flow is discussed, highlighting the potential and the unique characteristics of the processing operations based on elongation flow, as compared to their shear-dominated counterparts.

Crystallization of a Self-Assembling Nucleator in Poly(l-lactide) Melt

In the present work, crystallization of a soluble nucleator N, N', N″-tricyclohexyl-1,3,5-benzenetricarboxylamide (TMC-328) in a poly(l-lactic acid) (PLLA) matrix has been studied at different temperatures. Based on the change in solubility with temperature, different levels of supersaturation of TMC-328 in a PLLA matrix can be obtained. This nucleator presents a fibrous structure produced via self-assembling and develops into an interconnected network when the temperature is lowered. The TMC-328 crystal nuclei density is quantified via optical microscopy, using the average distance of the adjacent fibrillar structure, which shows a steady decrease with the decrease in temperature. The crystallization rates of TMC-328 were assessed through rheological measurements of network formation. Both fibrils' density and crystallization kinetics display a power law dependence on supersaturation. For the first time, the solid-melt interfacial energy, the size of the critical nucleus, and the number of molecules making up the critical nucleus of the nucleator TMC-328 in the PLLA matrix have been determined by adopting the classical nucleation theory. The subsequent crystallization of PLLA induced by this nucleator was investigated as a function of the fibrils' spatial density. The crystallization rate of PLLA is enhanced with the increase in the TMC-328 fibrils' density because of the availability of a larger nucleating surface. The self-assembled fibril of TMC-328 can serve as shish to form a hybrid shish-kebab structure after the crystallization of PLLA, regardless of the number of nucleation sites.

Investigation on the α/δ Crystal Transition of Poly(l-lactic Acid) with Different Molecular Weights

Poly(l-lactic acid) (PLLA) crystal possesses a complex polymorphism, and the formation mechanism of various crystal forms has been a hot research topic in the field of polymer condensate matter. In this research, five kinds of PLLA with different molecular weights were prepared by ring-opening polymerization with strict dehydration operations and multistep purification treatments. Then, thin film isothermal crystallization experiments were carried out to obtain crystallized samples. Previous research has proven that the PLLA α crystal form is usually formed at a temperature above 120 °C and the PLLA δ (or α') crystal form is usually formed at a temperature below 120 °C. However, in this research, the characterization results indicated that the PLLA crystal changed from δ form to α form with the decrease of molecular weight at a temperature of 80 °C. Considering the molecular weight effect, the paper argued that the transitions of the α/δ crystal form are not only associated with temperature, but also related to entanglement state before crystallization. The small-angle X-ray scattering of the PLLA crystal and rheology analysis of the PLLA melt before crystallization further proved the significant role of entanglement. Finally, we tentatively proposed the entanglement effect mechanism on the transitions of the α/δ crystal form.

In Situ Visualization for Control of Nano-Fibrillation Based on Spunbond Processing Using a Polypropylene/Polyethylene Terephthalate System

In situ generation of polyethylene terephthalate (PET) nanofibrils in polypropylene (PP) microfibers via fiber spinning in a spunbond process was studied in this work. The effects of polymer flow rate and air speed in the drafter on the formation of PET fibrils were investigated using a pilot scale machine. An in-situ visualization technique was applied to examine the fiber evolution events and stretch profile at die exit. A scanning electron microscope was used to analyze and investigate the morphology of the dispersed domain. The PET dispersed phase was fibrillated within the PP matrix such that a nonofibrillated composite containing fibrils with an average size around 100 nm was obtained. It was found that the final fibril size directly depends on the degree of die swell, the air speed and the polymer flow rate. It was also found that the in situ observed size of the micro-scale PP/PET fibers was well correlated to the size of the nano-scale PET fibers formed in the PP matrix. The visualization results revealed that a smaller fibril diameter was obtainable by increasing the stretching on the spin line and/or decreasing the die swell.

Kinked Bisamides as Efficient Supramolecular Foam Cell Nucleating Agents for Low-Density Polystyrene Foams with Homogeneous Microcellular Morphology

Polystyrene foams have become more and more important owing to their lightweight potential and their insulation properties. Progress in this field is expected to be realized by foams featuring a microcellular morphology. However, large-scale processing of low-density foams with a closed-cell structure and volume expansion ratio of larger than 10, exhibiting a homogenous morphology with a mean cell size of approximately 10 µm, remains challenging. Here, we report on a series of 4,4′-diphenylmethane substituted bisamides, which we refer to as kinked bisamides, acting as efficient supramolecular foam cell nucleating agents for polystyrene. Self-assembly experiments from solution showed that these bisamides form supramolecular fibrillary or ribbon-like nanoobjects. These kinked bisamides can be dissolved at elevated temperatures in a large concentration range, forming dispersed nano-objects upon cooling. Batch foaming experiments using 1.0 wt.% of a selected kinked bisamide revealed that the mean cell size can be as low as 3.5 µm. To demonstrate the applicability of kinked bisamides in a high-throughput continuous foam process, we performed foam extrusion. Using 0.5 wt.% of a kinked bisamide yielded polymer foams with a foam density of 71 kg/m³ and a homogeneous microcellular morphology with cell sizes of ≈10 µm, which is two orders of magnitude lower compared to the neat polystyrene reference foam with a comparable foam density.

Nanofibrous Foams of Poly(3-hydroxybutyrate)/Cellulose Nanocrystal Composite Fabricated Using Nonsolvent-Induced Phase Separation

In this study, we fabricated nanofibrous foams of neat poly(3-hydroxybutyrate) (PHB) and PHB/cellulose nanocrystal (CNC) nanocomposite using nonsolvent-induced phase separation (NIPS) followed by solvent extraction. Two different nonsolvents, tetrahydrofuran (THF) and 1,4-dioxane (Diox), in combination with the solvent, chloroform (CF), were used for NIPS. The parameters of NIPS-derived crystallization kinetics were calculated using Avrami analysis of time-dependent infrared spectral measurements. The lower viscosity and poorer PHB affinity of THF than those of Diox resulted in rapid crystallization and gelation rate, which in turn resulted in higher strength of the foam. The mechanical reinforcement by the incorporation of CNCs was achieved for the composite foam prepared in Diox/CF but not in THF/CF, owing to the relatively better dispersion of the CNCs in Diox than that in THF. A rapid rate of NIPS-derived crystallization and gelation was achieved in THF/CF with the incorporation of CNCs, indicating the effective crystal nucleation of CNCs. However, the presence of CNCs deaccelerated the crystallization in Diox/CF, indicating that the inhibition effect of PHB mobility became more dominant than the nucleation effect of CNCs; this was because the CNC dispersion became more homogeneous in Diox/CF. In vitro cell viability assays exhibited excellent cytocompatibility of the foams, thereby showing potential for use in biomedical applications.

Relationship between the Processing, Structure, and Properties of Microfibrillar Composites

The relationship between processing, morphology, and properties of polymeric materials has been the subject of numerous studies of academic and industrial research. Finding an answer to this question might result in guidelines on how to design polymeric materials. Microfibrillar composites (MFCs) are an interesting class of polymer-polymer composites. The advantage of the MFC concept lies in developing in situ microfibrils by which a perfect homogeneous distribution of the reinforcement in the matrix can be achieved. Their potentially excellent mechanical properties are strongly dependent on the aspect ratio of the fibrils, which is developed through a three-stage production process: melt blending, fibrillation, and isotropization. During melt blending, the polymers undergo different morphological changes, such as a breakup and coalescence of the droplets, which play a crucial role in defining the microstructure. During processing, various parameters may affect the morphology of the MFCs, which must be taken into account. Besides the processing parameters, the microstructure of the composite is dependent on the composition ratio of the blend and viscosity of the components, as well as the dispersion and distribution of the microfibrils. The objective here is to outline this importance and bring together an overview of the processing-structure-property relationship for MFCs.

Tunable Tensile Properties of Polypropylene and Polyethylene Terephthalate Fibrillar Blends through Micro-/Nanolayered Extrusion Technology

Fiber-reinforcement is a well-established technique to enhance the tensile properties of polymer composites, which is achieved via changing the reinforcing material concentration and orientation. However, the conventional method can be costly and may lead to poor compatibility issues. To overcome these challenges, we demonstrate the use of micro-/nanolayer (MNL) extrusion technology to tune the mechanical properties of polypropylene (PP)/polyethylene terephthalate (PET) fibrillar blends. PET nanofibers-in-PP microfiber composites, with 3, 7, and 15 wt.% PET, are first prepared using a spunbond system to induce high aspect-ratio PET nanofibers. The PP/PET fibers are then reprocessed in an MNL extrusion system and subjected to shear and extensional flow fields in the channels of the uniquely designed layer multipliers. Increasing the mass flow rate and number of multipliers is shown to orient the PET nanofibers along the machine direction (MD), as confirmed via scanning electron microscopy. Tensile tests reveal that up to a 45% and 46% enhancement in elastic modulus and yield strength are achieved owing to the highly aligned PET nanofibers along the MD under strongest processing conditions. Overall, the range of tensile properties obtained using MNL extrusion implies that the properties of fiber-reinforced composites can be further tuned by employing this processing technique.

Increasing cell density/decreasing cell size to produce microcellular and nanocellular thermoplastic foams: A review

Nowadays, polymeric foams have attracted particular attention in scientific and industrial societies due to their unique properties, such as high strength to weight ratio, excellent thermal and sound insulation, and low cost. Researchers have shown that the extraordinary properties of polymeric foams such as superior thermal insulation, can be achieved by increasing the cell density/decreasing the cell size. In this regard, firstly, the most important foaming processes, i.e. batch, extrusion, and injection molding are studied in the present research. Then, cell nucleation stage as the most crucial phenomenon for achieving high cell density/small cell size is investigated in detail. In the next step, the most important researches in the field of polymeric foams are introduced in which the largest cell densities/smallest cell sizes have been achieved. The investigations show that the most remarkable results (highest cell densities/smallest cell sizes) belong to the batch process. Also, the use of nucleating agents, increasing the solubility of blowing agent into the polymer, and the use of nanoparticles are the most efficient solutions to achieve microcellular and nanocellular structures.

Effects of pressure drop rate and CO2 content on the foaming behavior of newly developed high-melt-strength polypropylene in continuous extrusion

We report systematic studies on the foamability of our novel high-melt-strength long-chain branched polypropylene under supercritical CO2. Continuous foaming experiments were conducted using a tandem extrusion system and a set of filamentary dies with similar pressure drops but different pressure drop rates. The foam expansion was controlled by varying the temperature at the die exit. Under identical CO2 loadings, the expansion ratio plotted as a function of die temperature exhibited similar shapes across multiple pressure drop rates. However, the shape of the curve varied across different amounts of CO2, under which the highest achievable expansion ratio occurred at a lower die temperature with increasing CO2 content. The cell density displayed strong dependence on both the pressure drop rate and the amount of dissolved CO2. The effect of the latter became more apparent at lower pressure drop rates. The average cell size decreased with increasing CO2 loading but generally showed weak dependence on pressure drop rate except at the highest value.

PLA/PA Bio-Blends: Induced Morphology by Extrusion

The effect of processing conditions on the final morphology of Poly(Lactic Acid) (PLA) with bio-based Polyamide 10.10 (PA) 70/30 blends is analyzed in this paper. Two types of PLA were used: Commercial (neat PLA) and a rheologically modified PLA (PLAREx), with higher melt elasticity produced by reactive extrusion. To evaluate the ability of in situ micro-fibrillation (f) of PA phase during blend compounding by twin-screw extrusion, two processing parameters were varied: i) Screw speed rotation (rpm); and ii) take-up velocity, to induce a hot stretching with different Draw Ratios (DR). The potential ability of PA-f in both bio-blends was evaluated by the viscosity (p) and elasticity (k') ratios determined from the rheological tests of pristine polymers. When PLAREx was used, the requirements for PA-f was fulfilled in the shear rate range observed at the extrusion die. Scanning electron microscopy (SEM) observations revealed that, unlike neat PLA, PLAREx promoted PA-f without hot stretching and the aspect ratio increased as DR increased. For neat PLA-based blends, PA-f was promoted during the hot stretching stage. DMTA analysis revealed that the use of PLAREx PLAREx resulted in a better mechanical performance in the rubbery region (T > Tg PLA-phase) due to the PA-f morphology obtained.