Cavitation-Mediated Fracture Energy Dissipation in Polylactide at Rubbery Soybean Oil-Based Block Copolymer Interfaces Formed via Reactive Extrusion

Fully Atom-Efficient Solvent-Mediated Biopolymer Manufacturing: A Base Case Illustrated with Macromolecular Surfactants Tailored to Stable Polymer-Water Interfaces

This work introduces a novel 1-pot, 0-waste, 0-VOC methodology for synthesizing polymeric surfactants using acrylated epoxidized soybean oil and acrylated glycerol as primary monomers. These macromolecular surfactants are synthesized via reversible addition-fragmentation chain transfer (RAFT) polymerization, allowing for tunable hydrophilic-lipophilic balance (HLB) and ionic properties. We characterize the copolymers' chemical composition and surface-active properties, and evaluate their effectiveness in forming and stabilizing emulsions of semiepoxidized soybean oil and poly(acrylated epoxidized high oleic soybean oil). Comprehensive analyses, including gel permeation chromatography, nuclear magnetic resonance spectroscopy, dynamic light scattering, particle size distribution, zeta potential, and critical micelle concentration, provide detailed insights into the copolymers and the emulsions they form. The results demonstrate that the RAFT-polymerized surfactants offer long-lasting stability and effectively disperse both common oil-in-water emulsions and highly viscous and hydrophobic polymer latexes. These surfactants outperform traditional small molecule surfactants by reducing particle size and preventing phase separation, even over extended storage periods. Stable polymer-water interfaces are achieved through HLB control, tailored by monomer composition, and the final product requires no additional purification since polymerization occurs in liquid surfactants. While small molecules contribute to rapid micelle formation, the polymeric components enhance long-term stability through steric repulsion and slower dynamics. This method enables even the emulsification of polymers with submicron particle size, which ordinarily requires emulsion polymerization. Integrating biobased polymeric surfactants with advanced polymer processing techniques opens new possibilities for transforming highly hydrophobic polymers into latexes, facilitating downstream applications. This innovation enhances the environmental sustainability of surfactant production and broadens the potential for polymer emulsification technologies. Additionally, the integrated solution-processing approach demonstrated here can be applied to other emerging polymers, where judiciously selected nonvolatile solvents facilitate the polymerization and play a role in the final application.

Super-Tough PLA-Based Blends with Excellent Stiffness and Greatly Improved Thermal Resistance via Interphase Engineering

Super-tough poly(lactic acid)/polycarbonate (PLA/PC) (50/50) blends with an excellent balance of stiffness, toughness, and thermal stability were systematically designed and characterized. Poly(methyl methacrylate) (PMMA) was utilized as a novel, highly effective nonreactive interphase to promote PLA-PC phase compatibility. Partial miscibility of PMMA with both PLA and PC produced strong molecular entanglements across the PLA-PC phase boundary followed by an excellent phase adhesion. This was predicted from interfacial energy measurements and supported by dynamic mechanical thermal analysis, morphological observations, and mechanical tests. Ternary PLA/PC/PMMA blends exhibited an exceptional set of stiffness, tensile and flexural strength, tensile and flexural ductility, and thermal stability together with improved impact strength compared with neat PLA and uncompatibilized PLA/PC blends. Addition of nonreactive polybutadiene-g-styrene-co-acrylonitrile (PB-g-SAN) impact modifier to the compatibilized blend resulted in further dramatic improvements in the dispersion state of PC and PMMA phase domains followed by the development of an interconnected structure of PC, PMMA, and PB-g-SAN domains in the PLA matrix. Such a network-like morphology, with rubbery particles percolated at the interface between the dispersed structures and surrounding PLA matrix, produced a tremendous increase in impact resistance (≈700 J/m) and tensile ductility (≈200% strain) while maintaining excellent stiffness (≥2.1 GPa). The combined effects of interfacial localization of impact modifier particles, network-like morphology (extended over the entire volume of the blend), and strong phase interactions between the components (due to mutual miscibility) are described to be responsible for super-tough behavior. The role of PMMA as an efficient interphase adhesion promoter in the toughened quaternary blends is also clarified. Impact fractography revealed multiple void formations, plastic growth of microvoids, and the formation of void-fibrillar structures around as well as inside the dispersed structures as the main micromechanical deformation processes responsible for massive shear yielding and plastic deformation of blends. Blends designed in this work offer remarkable improvements in tensile and flexural ductility, impact resistance, and heat deflection temperature compared with neat PLA resin. The overall characteristics of these blend systems are comparable and/or superior to those of several commercial thermoplastic resins.