Thermal, thermomechanical and structural properties of recycled polyethylene terephthalate (rPET)/waste marble dust composites

The main objective of this work is to review the capability of using waste marble dust (MD) particles as reinforcing materials in recycled polymeric composites to achieve environmentally friendly materials. In the present study, polymer composites were fabricated from recycled polyethylene terephthalate (rPET) and MD and then analyzed for their structural and thermal properties. Preparation of rPET-based composites containing 0-20 wt% MD was carried out through extrusion and injection molding. For their characterization Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and dynamic mechanical analysis (DMA) were applied. The DSC analysis revealed a nucleating effect of MD on rPET, which was manifested in a higher crystallization temperature (196.7 °C ⇒ 204.4 °C); however, the marble particles were also found to hamper chain mobility, thereby decreasing the crystallinity ratio (23.7 % ⇒ 19.2 %) of rPET and altering its crystalline structure. According to the TGA measurements, a slight increase occurred in the thermal stability of rPET, its major decomposition temperature increased from 446 °C to 451 °C when 20 wt% MD was incorporated into it. DMA showed an improved stiffness in the entire investigated temperature range for MD-filled composites versus neat rPET. Additionally, several factors were derived from the DMA data, including the effectiveness factor, degree of entanglement, and reinforcing efficiency factor which all suggested a decent interaction between the components indicating a proper reinforcing ability of marble powder. However, above 5 wt% MD content the reinforcing efficiency deteriorated due to the agglomeration of filler particles, which was also supported by scanning electron microscopic images.

Comparing the Performance of Raman and Near-Infrared Imaging in the Prediction of the In Vitro Dissolution Profile of Extended-Release Tablets Based on Artificial Neural Networks

In this work, the performance of two fast chemical imaging techniques, Raman and near-infrared (NIR) imaging is compared by utilizing these methods to predict the rate of drug release from sustained-release tablets. Sustained release is provided by adding hydroxypropyl methylcellulose (HPMC), as its concentration and particle size determine the dissolution rate of the drug. The chemical images were processed using classical least squares; afterwards, a convolutional neural network was applied to extract information regarding the particle size of HPMC. The chemical images were reduced to an average HPMC concentration and a predicted particle size value; these were used as inputs in an artificial neural network with a single hidden layer to predict the dissolution profile of the tablets. Both NIR and Raman imaging yielded accurate predictions. As the instrumentation of NIR imaging allows faster measurements than Raman imaging, this technique is a better candidate for implementing a real-time technique. The introduction of chemical imaging in the routine quality control of pharmaceutical products would profoundly change quality assurance in the pharmaceutical industry.

Convolutional neural network-based evaluation of chemical maps obtained by fast Raman imaging for prediction of tablet dissolution profiles

In this work, the capabilities of a state-of-the-art fast Raman imaging apparatus are exploited to gain information about the concentration and particle size of hydroxypropyl methylcellulose (HPMC) in sustained release tablets. The extracted information is utilized to predict the in vitro dissolution profile of the tablets. For the first time, convolutional neural networks (CNNs) are used for the processing of the chemical images of HPMC distribution and to directly predict the dissolution profile based on the image. This new method is compared to wavelet analysis, which gives a quantification of the texture of HPMC distribution, carrying information regarding both concentration and particle size. A total of 112 training and 32 validation tablets were used, when a CNN was used to characterize the particle size of HPMC, the dissolution profile of the validation tablets was predicted with an average f₂ similarity value of 62.95. Direct prediction based on the image had an f₂ value of 54.2, this demonstrates that the CNN is capable of recognizing the patterns in the data on its own. The presented methods can facilitate a better understanding of the manufacturing processes, as detailed information becomes available with fast measurements.

Plastic waste from marine environment: Demonstration of possible routes for recycling by different manufacturing technologies

The increasing amount of marine plastic waste poses challenges including, not only the collection, but also the subsequent recyclability of the plastic. An artificial accelerated weathering procedure was developed, which modelled the marine environment and investigated the recyclability of weathered and non-weathered PET. Marine conditions were simulated for poly(ethylene terephthalate) (PET) bottle material and high-density polyethylene (HDPE) cap material. It consisted of 2520 h cyclical weathering, alternating the sample between a salt spray and a Xenon-chamber-this corresponds to roughly 3-4 years on the surface of an ocean. It was proved that the molecular weight of PET is a function of weathering time and can be described mathematically. Microscopic examination of the surface of the PET bottles and HDPE caps proved that these surfaces were damaged. After weathering, manufacturing tests were performed on the PET material by extrusion, injection moulding, 3D printing and thermoforming. Quantitative comparison between products manufactured by the same technology was performed in order to compare the qualities of products made from original PET, non-weathered PET waste, which was the example of classical recycling, and weathered PET. In the case of products made from weathered PET, certain mechanical and optical properties (e.g. impact strength and transparency) were significantly impaired compared to the original PET and the recycled, non-weathered PET. Certain other properties (e.g. strength and rigidity) did not change significantly. It was proved that the samples from weathered plastic material can be successfully recycled mechanically and used to manufacture plastic products.

Development of Flame-Retarded Nanocomposites from Recycled PET Bottles for the Electronics Industry

Recycled polyethylene-terephthalate (rPET) nanocomposites of reduced flammability were prepared by combining aluminum-alkylphosphinate (AlPi) flame retardant (FR) and natural montmorillonite (MMT), in order to demonstrate that durable, technical products can be produced from recycled materials. During the development of the material, by varying the FR content, the ratio and the type of MMTs, rheological, morphological, mechanical and flammability properties of the nanocomposites were comprehensively investigated. Related to the differences between the dispersion and nucleation effect of MMT and organo-modified MMT (oMMT) in rPET matrix, analyzed by Scanning Electron Microscopy (SEM), Energy Dispersive X-Ray Spectroscopy (EDS) and Differential Scanning Calorimetry (DSC), mechanical properties of the nanocomposites changed differently. The flexural strength and modulus were increased more significantly by adding untreated MMT than by the oMMT, however the impact strength was decreased by both types of nanofillers. The use of different type of MMTs resulted in contradictory flammability test result; time-to-ignition (TTI) during cone calorimeter tests decreased when oMMT was added to the rPET, however MMT addition resulted in an increase of the TTI also when combined with 4% FR. The limiting oxygen index (LOI) of the oMMT containing composites decreased independently from the FR content, however, the MMT increased it noticeably. V0 classification according to the UL-94 standard was achieved with as low as 4% FR and 1% MMT content. The applicability of the upgraded recycled material was proved by a pilot experiment, where large-scale electronic parts were produced by injection molding and characterized with respect to the commercially available counterparts.

Time Dependence of Morphology and Mechanical Properties of Injection Molded Recycled PET

During research, injection molded samples were prepared from recycled poly(ethylene-terephthalate) granulate, and their mechanical properties were investigated as a function of time. To understand the changes in mechanical properties, both morphology of injection molded samples and recycled granulates were investigated. A three-phase morphological model was applied for the evaluation of morphological properties while mechanical properties were determined by tensile and impact tests. Relationship was found between morphological and mechanical characteristics as a function of time elapsed since production. Crystalline ratio, tensile strength, and modulus of injection molded specimens increased while impact strength decreased in the four weeks after production.

Effects of SEBS-g-MA on Rheology, Morphology and Mechanical Properties of PET/HDPE Blends

The effects of additive styrene/ethylene-butylene/styrene copolymer grafted with maleic anhydride (SEBS-g-MA) were investigated on the rheology, morphology and mechanical properties of a polyethylene terephthalate (PET)/high density polyethylene (HDPE) blend. The ratio of the two components was changed in small increments to track phase inversion. The rheology measurements show that SEBS-g-MA acts differently on HDPE and PET, as different morphologies are formed due to viscosity ratio change. With the help of electron microscopy various phases after extrusion and after injection molding were revealed and identified. Because of the high viscosity of HDPE the co-continuous morphology was immediately formed when PET reached 30 vol%. The range of the co-continuous structure of the blend was wider when SEBS-g-MA was added, and the elongation at break also improved as additive content increased, without a significant strength decrease. The divergence of the mechanical properties from the theoretical value, i.e. the value determined by the mixing rule, can be explained by the changing phase structure.

Alternative polymer separation technology by centrifugal force in a melted state

In order to upgrade polymer waste during recycling, separation should take place at high purity. The present research was aimed to develop a novel, alternative separation opportunity, where the polymer fractions were separated by centrifugal force in melted state. The efficiency of the constructed separation equipment was verified by two immiscible plastics (polyethylene terephthalate, PET; low density polyethylene, LDPE), which have a high difference of density, and of which large quantities can also be found in the municipal solid waste. The results show that the developed equipment is suitable not only for separating dry blended mixtures of PET/LDPE into pure components again, but also for separating prefabricated polymer blends. By this process it becomes possible to recover pure polymer substances from multi-component products during the recycling process. The adequacy of results was verified by differential scanning calorimetry (DSC) measurement as well as optical microscopy and Raman spectroscopy.

Effect of processing technology on the morphological, mechanical and electrical properties of conductive polymer composites

Conducting carbon/polypropylene (PP) and carbon/poly(butylene terephthalate) (PBT) composites containing crystalline natural graphite and carbon black (CB) were prepared by compression and injection molding. The effect of the processing technology on the electrical, mechanical, and morphological properties was investigated. Determination of the constant torque at the end of the mixing process and differential scanning calorimetric (DSC) measurements showed that graphite had better connectivity with the more polar matrix (PBT) than with the less polar one (PP). Scanning electron microscopy (SEM) studies showed that compression molding results in a homogeneous structure, while injection molding results in a skin-core structure with different orientations. Layered electrical conductivity studies showed that the electrical conductivity of the compression molded samples did not change along the thickness of the sample, while that of the injection molded samples changed throughout the material, which is due to the different structures developed with each type of processing.