Injection Molded Novel Biocomposites from Polypropylene and Sustainable Biocarbon

Wood Residue-Derived Biochar as a Low-Cost, Lubricating Filler in Poly(butylene succinate-co-adipate) Biocomposites

This study focused on the development of a novel biocomposite material formed by a thermoplastic biodegradable polyester, poly(butylene succinate-co-adipate) (PBSA), and a carbonaceous filler as biochar (BC) derived by the pyrolysis of woody biomass waste. Composites with various BC contents (5, 10, 15, and 20 wt.%) were obtained by melt extrusion and investigated in terms of their processability, thermal, rheological, and mechanical properties. In all the composites, BC lowered melt viscosity, behaving as a lubricant, and enhancing composite extrudability and injection moulding at high temperatures up to 20 wt.% of biochar. While the use of biochar did not significantly change composite thermal stability, it increased its stiffness (Young modulus). Differential scanning calorimeter (DSC) revealed the presence of a second crystal phase induced by the filler addition. Furthermore, results suggest that biochar may form a particle network that hinders polymer chain disentanglement, reducing polymer flexibility. A biochar content of 10 wt.% was selected as the best trade-off concentration to improve the composite processability and cost competitiveness without compromising excessively the tensile properties. The findings support the use of biochar as a sustainable renewable filler and pigment for PBSA. Biochar is a suitable candidate to replace more traditional carbon black pigments for the production of biodegradable and inexpensive innovative PBSA composites with potential fertilizing properties to be used in agricultural applications.

Recent Advances in Biochar Polymer Composites

“Biochar” (BC) is the solid residue recovered from the thermal cracking of biomasses in an oxygen-poor atmosphere. Recently, BC has been increasingly explored as a sustainable, inexpensive, and viable alternative to traditional carbonaceous fillers for the development of polymer-based composites. In fact, BC exhibits high thermal stability, high surface area, and electrical conductivity; moreover, its main properties can be properly tuned by controlling the conditions of the production process. Due to its intriguing characteristics, BC is currently in competition with high-performing fillers in the formulation of multi-functional polymer-based composites, inducing both high mechanical and electrical properties. Moreover, BC can be derived from a huge variety of biomass sources, including post-consumer agricultural wastes, hence providing an interesting opportunity toward a “zero waste” circular bioeconomy. This work aims at providing a comprehensive overview of the main achievements obtained by combining BC with several thermoplastic and thermosetting matrices. In particular, the effect of the introduction of BC on the overall performance of different polymer matrices will be critically reviewed, highlighting the influence of differently synthesized BC on the final performance and behavior of the resulting composites. Lastly, a comparative perspective on BC with other carbonaceous fillers will be also provided.

Statistical Design of Biocarbon Reinforced Sustainable Composites from Blends of Polyphthalamide (PPA) and Polyamide 4,10 (PA410)

A full factorial design with four factors (the ratio of polyphthalamide (PPA) and polyamide 4,10 (PA410) in the polymer matrix, content percent of biocarbon (BioC), the temperature at which it was pyrolyzed and the presence of a chain extender (CE)), each factor with two levels (high and low), was carried out to optimize the mechanical properties of the resulting composites. After applying a linear model, changes in tensile strength, elongation at break and impact energy were not statistically significant within the considered material space, while the ones in the flexural modulus, the tensile modulus, density and heat deflection temperature (HDT) were. The two most influential factors were the content of BioC and its pyrolysis temperature, followed by the content of PPA. The affinity of PPA with a high-temperature biocarbon and the affinity of PA410 with a lower-temperature biocarbon, appear to explain the mechanical properties of the resulting composites. The study also revealed that the addition of CE hindered the mechanical properties. By maximizing the flexural modulus, tensile modulus and HDT, while minimizing the density, the optimal composite predicted is an 80 [PPA:PA410 (25:75)] wt% polymer composite, with 20 wt% of a BioC, pyrolyzed at a calculated 823 °C.

Immobilization of Caraway Essential Oil in a Polypropylene Matrix for Antimicrobial Modification of a Polymeric Surface

This study investigates antibacterial polymer composites based on polypropylene as modified by caraway essential oil at various concentrations, the latter immobilized on a talc. The caraway essential oil is incorporated in the polypropylene by a thermoplastic processing method. Analysis of the morphology of the composites was carried out by scanning electron microscopy. The chemical composition of the caraway essential oil in addition to its efficiency of incorporation and release were evaluated by GC/MS and Pyrolysis-GC/MS techniques, respectively. Determination was made as to the influence of such incorporation on thermal and tensile properties of the samples, while antibacterial activity was evaluated through conducting disk diffusion tests and measurement with adherence to the ISO 22196:2011 standard. It was found that incorporating the caraway essential oil in the samples did not affect the homogeneity of the thermoplastic-processed composites at any studied concentration. Stress–strain analysis confirmed the plasticizing effect of the essential oil in the polypropylene matrix, in addition to which, differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) analysis revealed that the prepared compositions with essential oil exhibited similar thermal properties to neat polypropylene. Results indicated significant antibacterial activity against Staphylococcus aureus and Escherichia coli at the concentration of essential oil of 4.9 ± 0.2 wt% and higher.

Sustainable Biocomposites from Recycled Bale Wrap Plastic and Agave Fiber: Processing and Property Evaluation

Plastic recycling to make sustainable materials is considered one of the biggest initiatives toward a greener environment and socioeconomic development. This research aims to investigate the properties of a blend of recycled bale wrap linear low-density polyethylene (rLLDPE) and polypropylene (PP) (rLLDPE/PP 50:50 wt % matrix), which was further reinforced with 25 wt % agave fiber prepared by injection-molding. Different ratios of a combined industrial compatibilizer (maleic anhydride-grafted PP/PE) were used (1-3 wt %), which were compared with a synthesized compatibilizer made from maleic anhydride-PP/rLLDPE in terms of mechanical and thermomechanical properties of the biocomposites. Incorporation of the compatibilizer in the composite improved the interfacial adhesion between the hydrophobic matrix and the hydrophilic agave fiber, which further increased the mechanical properties and heat deflection temperature of the composite. Scanning electron microscopy showed enhanced compatibility and adhesion between the fiber and the matrix by inclusion of 2 wt % compatibilizer. The synthesized compatibilizer-blended composite showed better mechanical properties than the industrial one, which indicates the potential application of this composite (around 62% recycled material) in the manufacture of packaging materials and commodity products.

Thermoformed Containers Based on Starch and Starch/Coffee Waste Biochar Composites

Biodegradable containers support zero-waste initiatives when alternative end-of-life scenarios are available (e.g., composting, bio digestion). Thermoplastic starch (TPS) has emerged as a readily biodegradable and inexpensive biomaterial that can replace traditional plastics in applications such as food service ware and packaging. This study has two aims. First, demonstrate the thermoformability of starch/polycaprolactone (PCL) as a thermoplastic material with varying starch loadings. Second, incorporate biochar as a sustainable filler that can potentially lower the cost and enhance compostability. Biochar is a stable form of carbon produced by thermochemical conversion of organic biomass, such as food waste, and its incorporation into consumer products could promote a circular economy. Thermoformed samples were successfully made with starch contents from 40 to 60 wt.% without biochar. Increasing the amount of starch increased the viscosity of the material, which in turn affected the compression molding (sheet manufacturing) and thermoforming conditions. PCL content reduced the extent of biodegradation in soil burial experiments and increased the strength and elongation at break of the material. A blend of 50:50 starch:PCL was selected for incorporating biochar. Thermoformed containers were manufactured with 10, 20, and 30 wt.% biochar derived from waste coffee grounds. The addition of biochar decreased the elongation at break but did not significantly affect the modulus of elasticity or tensile strength. The results demonstrate the feasibility of using starch and biochar for the manufacturing of thermoformed containers.

Hybrid biocomposites from polypropylene, sustainable biocarbon and graphene nanoplatelets

Polypropylene (PP) is an attractive polymer for use in automotive parts due to its ease of processing, hydrophobic nature, chemical resistance and low density. The global shift towards eliminating non-renewable resource consumption has promoted research of sustainable biocarbon (BioC) filler in a PP matrix, but this material often leads to reduction in composite strength and requires additional fillers. Graphene nano-platelets (GnPs) have been the subject of considerable research as a nanofiller due to their strength, while maleic anhydride grafted polypropylene (MA-g-PP) is a commonly used compatibilizer for improvement of interfacial adhesion in composites. This study compared the thermo-mechanical properties of PP/BioC/MA-g-PP/GnP composites with varying wt.% of GnP. Morphological analysis revealed uniform dispersion of BioC, while significant agglomeration of GnPs limited their even dispersion throughout the PP matrix. In the optimal blend of 3 wt.% GnP and 17 wt.% BioC biocontent, tensile strength and modulus increased by ~19% and ~22% respectively, as compared to 20 wt.% BioC biocomposites. Thermal stability and performance enhancement occurred through incorporation of the fillers. Thus, hybridization of fillers in the compatibilized matrix presents a promising route to the enhancement of material properties, while reducing petroleum-based products through use of sustainable BioC filler in composite structures.

Insights on the structure-performance relationship of polyphthalamide (PPA) composites reinforced with high-temperature produced biocarbon

Biocarbon-filled polyphthalamide composites were made, achieving comparable mechanical and thermal characteristics to talc-filled ones, at a lower density.