Recent progress on biodegradable polylactic acid based blends and their biocomposites: A comprehensive review

Being less dependent on non-renewable resources as well as protecting the environment from waste streams have become two critical primers for a global movement toward replacing conventional plastics with renewable and biodegradable polymers. Despite all these efforts, only a few biodegradable polymers have paved their way successfully into the market. Polylactic acid is one of these biodegradable polymers that has been investigated thoroughly by researchers as well as manufactured on a large industrial scale. It is synthesized from lactic acid obtained mainly from the biological fermentation of carbohydrates, which makes this material a renewable polymer. Besides its renewability, it benefits from some attractive mechanical performances including high strength and stiffness, though brittleness is a major drawback of this biopolymer. Accordingly, the development of blends and biocomposites based on polylactic acid with highly flexible biodegradable polymers, specifically poly(butylene adipate co terephthalate) has been the objective of many investigations recently. This paper focuses on the blends and biocomposites based on these two biopolymers, specifically their mechanical, rheological, and biodegradation, the main characteristics that are crucial for being considered as a biodegradable substitution for conventional non-biodegradable polymers.

Effect of Chain Extending Cross-Linkers on the Disintegration Behavior of Composted PBAT/PLA Blown Films

A biodegradable blend of PBAT-poly(butylene adipate-co-terephthalate)-and PLA-poly(lactic acid)-for blown film extrusion was modified with four multi-functional chain extending cross-linkers (CECL). The anisotropic morphology introduced during film blowing affects the degradation processes. Given that two CECL increased the melt flow rate (MFR) of tris(2,4-di-tert-butylphenyl)phosphite (V1) and 1,3-phenylenebisoxazoline (V2) and the other two reduced it (aromatic polycarbodiimide (V3) and poly(4,4-dicyclohexylmethanecarbodiimide) (V4)), their compost (bio-)disintegration behavior was investigated. It was significantly altered with respect to the unmodified reference blend (REF). The disintegration behavior at 30 and 60 °C was investigated by determining changes in mass, Young's moduli, tensile strengths, elongations at break and thermal properties. In order to quantify the disintegration behavior, the hole areas of blown films were evaluated after compost storage at 60 °C to calculate the kinetics of the time dependent degrees of disintegration. The kinetic model of disintegration provides two parameters: initiation time and disintegration time. They quantify the effects of the CECL on the disintegration behavior of the PBAT/PLA compound. Differential scanning calorimetry (DSC) revealed a pronounced annealing effect during storage in compost at 30 °C, as well as the occurrence of an additional step-like increase in the heat flow at 75 °C after storage at 60 °C. The disintegration consists of processes which affect amorphous and crystalline phase of PBAT in different manner that cannot be understood by a hydrolytic chain degradation only. Furthermore, gel permeation chromatography (GPC) revealed molecular degradation only at 60 °C for the REF and V1 after 7 days of compost storage. The observed losses of mass and cross-sectional area seem to be attributed more to mechanical decay than to molecular degradation for the given compost storage times.

Morphology and Performance Relationship Studies on Poly(3-hydroxybutyrate-co-3-hydroxyvalerate)/Poly(butylene adipate-co-terephthalate)-Based Biodegradable Blends

Biodegradable poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV)/poly(butylene adipate-co-terephthalate) (PBAT) blends hold great potential for use in sustainable packaging applications for their advanced performance. Understanding the structure-property relationship in the blends at various proportions is significantly important for their future application, which is addressed in this work. The study found that the inherent brittleness of PHBV can only be modified with the addition of 50 wt % PBAT, where co-continuous structures formed in the blend as revealed by scanning electron microscopy (SEM) analysis. The elongation at break (%) of the blends increased from 3.81 (30% PBAT) to 138.5% (50% PBAT) and 345.3% (70 wt % PBAT), respectively. The fibrous structures of the PBAT formed during breaking are beneficial for energy dissipation, which greatly increased the toughness of the blends. Both the SEM observation and glass-transition temperature study by dynamic mechanical analysis indicated that the PHBV and PBAT are naturally immiscible. However, by simply mixing the two polymers with different composition ratios, the properties including melt flow index, heat deflection temperature, and mechanical properties can be tailored for different processing methods and applications. Our research work herein illustrates the fundamental structure-property relationship in this popular blend of PHBV/PBAT, aiming to guide the future modification direction in improving their properties and realizing their commercial applications in different scenarios.

Process-Induced Morphology of Poly(Butylene Adipate Terephthalate)/Poly(Lactic Acid) Blown Extrusion Films Modified with Chain-Extending Cross-Linkers

Process-induced changes in the morphology of biodegradable polybutylene adipate terephthalate (PBAT) and polylactic acid (PLA) blends modified with various multifunctional chain-extending cross-linkers (CECLs) are presented. The morphology of unmodified and modified films produced with blown film extrusion is examined in an extrusion direction (ED) and a transverse direction (TD). While FTIR analysis showed only small peak shifts indicating that the CECLs modify the molecular weight of the PBAT/PLA blend, SEM investigations of the fracture surfaces of blown extrusion films revealed their significant effect on the morphology formed during the processing. Due to the combined shear and elongation deformation during blown film extrusion, rather spherical PLA islands were partly transformed into long fibrils, which tended to decay to chains of elliptical islands if cooled slowly. The CECL introduction into the blend changed the thickness of the PLA fibrils, modified the interface adhesion, and altered the deformation behavior of the PBAT matrix from brittle to ductile. The results proved that CECLs react selectively with PBAT, PLA, and their interface. Furthermore, the reactions of CECLs with PBAT/PLA induced by the processing depended on the deformation directions (ED and TD), thus resulting in further non-uniformities of blown extrusion films.

The Effects of Chain-Extending Cross-Linkers on the Mechanical and Thermal Properties of Poly(butylene adipate terephthalate)/Poly(lactic acid) Blown Films

This study investigates the effects of four multifunctional chain-extending cross-linkers (CECL) on the processability, mechanical performance, and structure of polybutylene adipate terephthalate (PBAT) and polylactic acid (PLA) blends produced using film blowing technology. The newly developed reference compound (M·VERA® B5029) and the CECL modified blends are characterized with respect to the initial properties and the corresponding properties after aging at 50 °C for 1 and 2 months. The tensile strength, seal strength, and melt volume rate (MVR) are markedly changed after thermal aging, whereas the storage modulus, elongation at the break, and tear resistance remain constant. The degradation of the polymer chains and crosslinking with increased and decreased MVR, respectively, is examined thoroughly with differential scanning calorimetry (DSC), with the results indicating that the CECL-modified blends do not generally endure thermo-oxidation over time. Further, DSC measurements of 25 µm and 100 µm films reveal that film blowing pronouncedly changes the structures of the compounds. These findings are also confirmed by dynamic mechanical analysis, with the conclusion that tris(2,4-di-tert-butylphenyl)phosphite barely affects the glass transition temperature, while with the other changes in CECL are seen. Cross-linking is found for aromatic polycarbodiimide and poly(4,4-dicyclohexylmethanecarbodiimide) CECL after melting of granules and films, although overall the most synergetic effect of the CECL is shown by 1,3-phenylenebisoxazoline.

Manipulating Crystallization for Simultaneous Improvement of Impact Strength and Heat Resistance of Plasticized Poly(l-lactic acid) and Poly(butylene succinate) Blends

Crystalline morphology and phase structure play a decisive role in determining the properties of polymer blends. In this research, biodegradable blends of poly(l-lactic acid) (PLLA) and poly(butylene succinate) (PBS) have been prepared by melt-extrusion and molded into specimens with rapid cooling. The crystalline morphology (e.g., crystallinity, crystal type and perfection) is manipulated by annealing the molded products from solid-state within a short time. This work emphasizes on the effects of annealing conditions on crystallization and properties of the blends, especially impact toughness and thermal stability. Phase-separation morphology with PBS dispersed particles smaller than 1 μm is created in the blends. The blend properties are successfully dictated by controlling the crystalline morphology. Increasing crystallinity alone does not ensure the enhancement of impact toughness. A great improvement of impact strength and heat resistance is achieved when the PLLA/PBS (80/20) blends are plasticized with 5% medium molecular-weight poly(ethylene glycol), and simultaneously heat-treated at a temperature close to the cold-crystallization of PLLA. The plasticized blend annealed at 92 °C for only 10 min exhibits ten-fold impact strength over the starting PLLA and slightly higher heat distortion temperature. The microscopic study demonstrates the fracture mechanism changes from crazing to shear yielding in this annealed sample.

Binary Green Blends of Poly(lactic acid) with Poly(butylene adipate-co-butylene terephthalate) and Poly(butylene succinate-co-butylene adipate) and Their Nanocomposites

Poly(lactic acid) (PLA) is the most widely produced biobased, biodegradable and biocompatible polyester. Despite many of its properties are similar to those of common petroleum-based polymers, some drawbacks limit its utilization, especially high brittleness and low toughness. To overcome these problems and improve the ductility and the impact resistance, PLA is often blended with other biobased and biodegradable polymers. For this purpose, poly(butylene adipate-co-butylene terephthalate) (PBAT) and poly(butylene succinate-co-butylene adipate) (PBSA) are very advantageous copolymers, because their toughness and elongation at break are complementary to those of PLA. Similar to PLA, both these copolymers are biodegradable and can be produced from annual renewable resources. This literature review aims to collect results on the mechanical, thermal and morphological properties of PLA/PBAT and PLA/PBSA blends, as binary blends with and without addition of coupling agents. The effect of different compatibilizers on the PLA/PBAT and PLA/PBSA blends properties is here elucidated, to highlight how the PLA toughness and ductility can be improved and tuned by using appropriate additives. In addition, the incorporation of solid nanoparticles to the PLA/PBAT and PLA/PBSA blends is discussed in detail, to demonstrate how the nanofillers can act as morphology stabilizers, and so improve the properties of these PLA-based formulations, especially mechanical performance, thermal stability and gas/vapor barrier properties. Key points about the biodegradation of the blends and the nanocomposites are presented, together with current applications of these novel green materials.

Evaluation of the Suitability of Poly(Lactide)/Poly(Butylene-Adipate-co-Terephthalate) Blown Films for Chilled and Frozen Food Packaging Applications

The use of biopolymers can reduce the environmental impact generated by plastic materials. Among biopolymers, blends made of poly(lactide) (PLA) and poly(butylene-adipate-co-terephthalate) (PBAT) prove to have adequate performances for food packaging applications. Therefore, the present work deals with the production and the characterization of blown films based on PLA and PBAT blends in a wide range of compositions, in order to evaluate their suitability as chilled and frozen food packaging materials, thus extending their range of applications. The blends were fully characterized: they showed the typical two-phase structure, with a morphology varying from fibrillar to globular in accordance with their viscosity ratio. The increase of PBAT content in the blends led to a decrease of the barrier properties to oxygen and water vapor, and to an increase of the toughness of the films. The mechanical properties of the most ductile blends were also evaluated at 4 °C and -25 °C. The decrease in temperature caused an increase of the stiffness and a decrease of the ductility of the films to a different extent, depending upon the blend composition. The blend with 40% of PLA revealed to be a good candidate for chilled food packaging applications, while the blend with a PLA content of 20% revealed to be the best composition as frozen food packaging material.

Improving the Toughness and Thermal Resistance of Polyoxymethylene/Poly(lactic acid) Blends: Evaluation of Structure-Properties Correlation for Reactive Processing

The study focuses on the development of polyoxymethylene (POM)/poly(lactic acid) (PLA) blends with increased impact and thermal resistance. The study was conducted in two phases; in the first part, a series of unmodified blends with PLA content of 25, 50, and 75 wt.% was prepared, while the second part focused on the modification of the PLA/POM (50/50) blends. An ethylene/butyl acrylate/glycidyl methacrylate terpolymer (E/BA/GMA) elastomer (EBA) was used to improve the impact strength of the prepared blends, while reactive blending was used to improve interfacial interactions. We used a multifunctional epoxy chain extender (CE) as the compatibilizer. Static tensile tests and notched Izod measurement were used to evaluate the mechanical performance of the prepared samples. The thermomechanical properties were investigated using dynamic mechanical thermal analysis (DMTA) analysis and heat deflection temperature (HDT)/Vicat softening temperature (VST) methods. The crystallinity was measured using differential scanning calorimetry (DSC) and wide-angle X-ray diffraction (WAXS) measurements, while the rheology was evaluated using a rotational rheometer. The paper also includes a structure analysis performed using the SEM method. The structural tests show partial miscibility of the POM/PLA systems, resulting in the perfect compatibility of both phases. The impact properties of the final blends modified by the EBA/CE system were found to be similar to pure POM resin, while the E modulus was visibly improved. Favorable changes were also noticeable in the case of the thermomechanical properties. The results of most of the conducted measurements and microscopic observations confirm the high efficiency of the reaction for PLA as well as for the modified POM/PLA mixtures.

Preparation and Characterization of Bio-Based PLA/PBAT and Cinnamon Essential Oil Polymer Fibers and Life-Cycle Assessment from Hydrolytic Degradation

Nowadays, the need to reduce the dependence on fuel products and to achieve a sustainable development is of special importance due to environmental concerns. Therefore, new alternatives must be sought. In this work, extruded fibers from poly (lactic acid) (PLA) and poly (butylene adipate-co-terephthalate) (PBAT) added with cinnamon essential oil (CEO) were prepared and characterized, and the hydrolytic degradation was assessed. A two-phase system was observed with spherical particles of PBAT embedded in the PLA matrix. The thermal analysis showed partial miscibility between PLA and PBAT. Mechanically, Young's modulus decreased and the elongation at break increased with the incorporation of PBAT and CEO into the blends. The variation in weight loss for the fibers was below 5% during the period of hydrolytic degradation studied with the most important changes at 37 °C and pH 8.50. From microscopy, the formation of cracks in the fiber surface was evidenced, especially for PLA fibers in alkaline medium at 37 °C. This study shows the importance of the variables that influence the performance of polyester-cinnamon essential oil-based fibers in agro-industrial applications for horticultural product preservation.

Effect of different sterilization methods on the properties of commercial biodegradable polyesters for single-use, disposable medical devices

The increasing employment of non-degradable polymers based single-use, disposable medical devices have led to huge environmental pressure. Replacement of non-degradable polymers with biodegradable alternatives could be one solution. Since terminal sterilization is a necessary procedure for medical devices to eliminate infections, in this paper, the modifications of sterilization on the transparency, yellow index, dimensional stability and mechanical properties of commercial biodegradable poly(lactic acid) (PLA), poly(butylenes adipate-co-terephthalate) (PBAT) and their blends were investigated. The samples were prepared by compression molding and exposed to four sterilization treatments including ethylene oxide gas (EtO), saturated steam (SS), electron beam (EB), and hydrogen peroxide gas plasma (HPGP). It is concluded that EB can be applied for the sterilization of all the materials investigated, while SS and EtO are not recommended for PLA, and HPGP is not for PBAT and PLA/PBAT blends. This study demonstrates that, when a suitable sterilization process is chosen, PLA has potential to be used for transparent medical devices such as the barrel of syringes or microfluidic chips, while PBAT and PLA/PBAT blends for other non-transparent medical packaging applications.

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.

Tailoring Heat-Seal Properties of Biodegradable Polymers through Melt Blending

In this study, we address heat-seal properties of poly (lactic acid) (PLA), blended with Poly (butylene adipate-co-terephthalate) (PBAT). The objective is to correlate blends crystalline structure and morphology to corresponding heat-seal of blends films. The SEM micrographs show a two-phase elongated morphology where stretched ellipsoids developed through elongational flow during the cast film process. To distinguish the effect of crystallization, we also prepared amorphous and crystalline PBAT films and then compared them to blends with PLA. Heat-sealed areas were created by putting film surfaces in intimate contact for 1 s at the pressure of 0.5 N/mm2 or Pa and in the temperature range of 70 to 140 °C. Thermal analysis shows that the crystalline structure of PBAT has a significant effect on shifting its heat-seal initiation temperature (Tsi) up to 20 °C. Regarding the blends, incorporation of PBAT as a dispersed phase lowers Tsi of blend samples. Here, gradual decrease in PBAT crystallinity caused by the hindering effect of PLA rigid molecules correlates with the shift in heat-seal initiation temperature. As mentioned above, elongated disperse morphology with higher aspect ratio of the dispersed phase compared to spherical dispersed domain, is formed through film cast process. This enhances the adhesion process by providing higher contact area. The blends also show higher toughness and better puncture resistance, which is an asset for flexible packaging applications and would enhance the mechanical performance of the seal layer.

Thermal and Mechanical Properties of Biodegradable Star-Shaped/Linear Polylactide Stereocomplexes

The 6-arm star-shaped poly(L-lactide) (6PLL)/linear poly(D-lactide) (1PDL) stereocomplex films were prepared by the solvent casting method. The influences of the 6PLL/1PDL blend ratios (75/25, 50/50, and 25/75 w/w) and 1PDL molecular weights (15,000, 30,000, and 60,000 g/mol) on the thermal and mechanical properties of the stereocomplex films were investigated. The 6PLL and 1PDLs had a single melting temperature (Tm) of homocrystallites at 174°C and 167°C, respectively. The 6PLL/1PDL blends had twoTms: a lowerTmof homocrystallites (160–173°C) and a higherTmof stereocomplex crystallites (219–228°C). The stereocomplex crystallinity and mechanical properties of the 6PLL/1PDL blend films were higher than those of 6PLL and 1PDL and were the highest in the 50/50 (w/w) blend ratio. However, the stereocomplex crystallinity of the 50/50 (w/w) 6PLL/1PDL blend films decreased and the mechanical properties increased as the molecular weight of 1PDL increased.

Phosphonium ionic liquids as new compatibilizing agents of biopolymer blends composed of poly(butylene-adipate-co-terephtalate)/poly(lactic acid) (PBAT/PLA)

Effect of phosphonium ionic liquids on the morphologies of PBAT/PLA blends.