Poly(glycidyl methacrylate) modified cellulose nanocrystals and their PBAT-based nanocomposites

Melt processing of cellulose nanocrystals (CNCs) reinforced nanocomposites is still a serious challenge due to the hydrophilic nature of CNCs and their severe agglomeration tendency within the polymer melt. In this study, chemical modification of CNC through grafting poly(glycidyl methacrylate) (PGMA) with various degrees was implemented. Wettability of the modified CNCs (mCNCs) were controlled and their structure was characterized through Fourier transform infrared spectroscopy (FTIR), X-ray photoelectron spectroscopy (XPS), optical microscopy, X-ray diffraction (XRD), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). The nanocomposites of polybutylene adipate terephthalate (PBAT) with 3 wt% CNC and mCNC were prepared using an internal melt mixer. To differentiate the effects of CNC and PGMA molecules on the final properties of nanocomposites, PBAT/PGMA compounds were separately prepared. To confirm the chain characterization and molecular weight of the synthesized PGMAs, 1H NMR and gel permeation chromatography (GPC) analysis were conducted. Melt rheological analysis, dynamic mechanical analysis (DMA), DSC, and atomic force microscopy (AFM) were used to monitor the mCNC dispersion quality and the effect of PGMA modification in PBAT compounds. The results revealed that grafting CNC with longer PGMA considerably improved the CNCs' dispersion quality within PBAT. Such dispersion enhancement of long-chain mCNCs and interfacial interaction of PGMA and PBAT resulted in a noticeable increase in storage modulus and complex viscosity of the final nanocomposites.

Synergistic Enhancement of Flame Retardancy Behavior of Glass-Fiber Reinforced Polylactide Composites through Using Phosphorus-Based Flame Retardants and Chain Modifiers

Flame retardancy properties of neat PLA can be improved with different phosphorus-based flame retardants (FRs), however, developing flame retardant PLA-based engineering composites with maintained mechanical performance is still a challenge. This study proposes symbiosis approaches to enhance the flame retardancy behavior of polylactide (PLA) composites with 20 wt% short glass fibers (GF). This was first implemented by exploring the effects of various phosphorus-based FRs up to 5 wt% in neat PLA samples. Among the used phosphorus-based FRs, the use of only 3 wt% of diphosphoric acid-based FR (P/N), melamine coated ammonium polyphosphate (APPcoated), and APP with melamine synergist (APP/Mel) resulted in achieving the V0 value in a vertical burning test in the neat PLA samples. In addition to their superior efficiency in improving the flame retardancy of neat PLA, P/N had the least negative effect on the final mechanical performance of PLA samples. When incorporated in PLA composites with 20 wt% GF, however, even with the use of 30 wt% P/N, the V0 value could not be obtained due to the candlewick effect. To resolve this issue, the synergistic effect of P/N and aromatic polycarbodiimide (PCDI) cross-linker or Joncryl epoxy-based chain-extender (CE) on the flame retardancy characteristics of composites was examined. Due to the further chain modification, which also enhances the melt strength of PLA, the dripping of composites in the vertical burning test terminated and the V0 value could be reached when using only 1 wt% PCDI or CE. According to the scanning electron microscopic analysis, the use of noted chain modifiers further homogenized the distribution and refined the particle size of P/N within the PLA matrix. Hence this could synergistically contribute to the enhancements of the fire resistance performance of the PLA composites. Such incorporation of P/N and chain modifiers further leads to the enhancement of the mechanical performance of PLA composites and hence the resultant product can be proposed as a promising durable bioplastic engineering product where fire risk exists.

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

Due to their light-weight and cost-effectiveness, cellular thermoplastic foams are considered as important engineering materials. On the other hand, additive manufacturing or 3D printing is one of the emerging and fastest growing manufacturing technologies due to its advantages such as design freedom and tool-less production. Nowadays, 3D printing of polymer compounds is mostly limited to manufacturing of solid parts. In this context, a merged foaming and printing technology can introduce a great alternative for the currently used foam manufacturing technologies such as foam injection molding. This perspective review article tackles the attempts taken toward initiating this novel technology to simultaneously foam and print thermoplastics. After explaining the basics of polymer foaming and additive manufacturing, this article classifies different attempts that have been made toward generating foamed printed structures while highlighting their challenges. These attempts are clustered into 1) architected porous structures, 2) syntactic foaming, 3) post-foaming of printed parts, and eventually 4) printing of blowing agents saturated filaments. Among these, the latest approach is the most practical route although it has not been thoroughly studied yet. A filament free approach that can be introduced as a potential strategy to unlock the difficulties to produce printed foam structures is also proposed.

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.

Effect of solvent type on the dispersion quality of spray-and freeze-dried CNCs in PLA through rheological analysis

Polylactide (PLA) nanocomposites with spray-and freeze-dried cellulose nanocrystals (i.e., SCNC and FCNC) were prepared through solution casting using four different solvents: tetrahydrofuran (THF), chloroform (CHL), dimethylformamide (DMF), and dimethyl sulfoxide (DMSO). Small amplitude oscillatory shear rheological analysis was extensively employed to explore the CNC dispersion quality in PLA. Overall, the rheological properties differences of PLA/SCNC and PLA/FCNC nanocomposites were not very significant. Moreover, the use of THF and CHL did not lead to a proper dispersion of CNCs in PLA due to their low dielectric constants. On the other hand, while the use of DMF was effective on the enhancement of CNC dispersion, DMSO could more dramatically lead to such enhancement due to its higher dielectric constant. The percolation threshold in PLA/SCNC nanocomposites prepared with DMF and DMSO was predicted around 1.52 and 0.12 wt% CNC, respectively. The crystallization behavior of PLA/nanocomposites prepared with DMF and DMSO were also explored.

Nanoclay Migration and the Rheological Response of PBAT/LDPE Blends

Blends of a poly(butylene adipate-co-terephthalate) (PBAT) and a low density polyethylene (LDPE) (80 wt%/20 wt%) were prepared through a twin screw extruder while incorporating 3 wt% Cloisite 30B (C30B) nanoclay that possessed a much higher affinity with PBAT. The blends were processed through three melt mixing strategies: ( i) direct mixing of all three components, (ii) mixing C30B and PBAT followed by mixing with LDPE, and (iii) mixing C30B and LDPE followed by mixing with PBAT. The rheological properties of each system were determined in small amplitude oscillatory shear (SAOS) experiments. The migration of C30B nanoparticles from the LDPE minor phase towards the PBAT matrix was then monitored in the blend nanocomposites prepared through strategy (iii) via SAOS time sweep experiments. It was firstly understood that the C30B migration could be detected during time sweep SAOS experiments. The migration time was observed to be frequency dependent due to the smaller length scales probed at larger frequencies. Such migration occurred even faster when the SAOS time sweep experiments were conducted at a higher temperature due to the viscosity reduction.

Microcellular foaming behavior of ether- and ester-based TPUs blown with supercritical CO2

The bead foaming behavior of ether- and an ester-based Tensor Processing Unit (TPU) resins were investigated in a lab-scale reactor using supercritical CO2 as the blowing agent. The samples were saturated at various saturation temperatures and the effects of hard segment crystallization during the saturation on the foaming behavior of the TPU samples were explored. The results revealed that the different HS crystallization tendencies and possible CO2 solubility differences in two TPU grades led to their different foaming behaviors. The ester-based TPU could be foamed within a wider saturation temperature range and revealed an easier cell growth and foam expansion while the ether-based TPU showed a more limited cell growth behavior and hence processing window. The effect of pre-annealing and hence the isothermally induced HS crystallization on the foaming behavior of the ether-based TPU and the influence of depressurization rate on the foaming behavior of ester-based TPU was also explored.

Effects of molecular weight and crystallizability of polylactide on the cellulose nanocrystal dispersion quality in their nanocomposites

This study investigated how cellulose nanocrystals (CNC) dispersion quality and its percolation network formation could be influenced when using polylactide (PLA) with various molecular weights and crystallizability. In this context, systematic rheological experiments were conducted on PLA/CNC nanocomposites prepared through solution casting method using dimethylformamide (DMF) as the solvent. It was found that lower CNC percolation concentrations could be obtained when a PLA matrix possesses lower molecular weight as the shorter chains and CNCs interpenetration could be facilitated during their dissolution in the solvent. On the other hand, the CNC percolation concentration was further lowered when the PLA with higher crystallizability was used. During the solvent evaporation step that occurred at 85 °C, the isothermal heterogeneous crystallization of PLA around the dispersed CNCs could prevent the driving force of the CNCs towards their re-agglomeration. Therefore, the finest CNC dispersion was appeared in the highly crystallizable low molecular weight PLA through which the rheological properties were dramatically improved and the thermal stability was significantly extended to higher temperatures. The crystallization behavior of the prepared nanocomposites was also analyzed using differential scanning calorimeter and X-ray diffractometer. The thermal degradation behavior of the PLA/CNC nanocomposites were examined through thermogravimetric and rheological analysis.

Lightweight polypropylene/stainless-steel fiber composite foams with low percolation for efficient electromagnetic interference shielding

Lightweight polypropylene/stainless-steel fiber (PP-SSF) composites with 15-35% density reduction were fabricated using foam injection molding. The electrical percolation threshold, through-plane electrical conductivity, and electromagnetic interference (EMI) shielding effectiveness (SE) of the PP-SSF composite foams were characterized and compared against the solid counterparts. With 3 wt % CO2 dissolved in PP as a temporary plasticizer and lubricant, the fiber breakage was significantly decreased during injection molding, and well-dispersed fibers with unprecedentedly large aspect ratios of over 100 were achieved. The percolation threshold was dramatically decreased from 0.85 to 0.21 vol %, accounting for 75% reduction, which is highly superior, compared to 28% reduction of the previous PP-carbon fiber composite foam.1 Unlike the case of carbon fiber,1 SSFs were much longer than the cell size, and the percolation threshold reduction of PP-SSF composite foams was thus primarily governed by the decreased fiber breakage instead of fiber orientation. The specific EMI SE was also significantly enhanced. A maximum specific EMI SE of 75 dB·g(-1)·cm(3) was achieved in PP-1.1 vol % SSF composite foams, which was much higher than that of the solid counterpart. Also, the relationships between the microstructure and properties were discussed. The mechanism of EMI shielding enhancement was also studied.

Processing and characterization of solid and foamed injection-molded polylactide with talc

Polylactide (PLA) suffers from poor processability due to its low melt strength and slow crystallization kinetics and it is thus very challenging to achieve uniformly distributed fine-celled PLA foams with high void fractions in injection molding process. In this work, the low-pressure structural foam molding of linear PLA with a relatively high void fraction of ∼30% was conducted and by fine tuning the talc content and the foaming and processing parameters, a relatively uniform fine-celled structure with improved cell size and cell density was successfully produced. The effects of twin-screw compounding and the addition of talc on the foaming behavior, structural uniformity, crystallinity, and mechanical properties of the solid and foamed PLA samples were investigated. The results showed that the addition of 5 wt.% talc significantly improved the foaming properties such as cell density, cell size, structural uniformity, and consequently improved the mechanical properties of foams. The twin-screw compounding before injection molding did not significantly change the foaming behavior, but adversely affected the mechanical properties of the solid and foamed PLA samples due to mechanical and thermal degradation. The changes in the mechanical properties were discussed in terms of the crystallinity, talc toughening effect, and foam quality.

The foamability of low-melt-strength linear polypropylene with nanoclay and coupling agent

In this work, the feasibility of producing microcellular foam by using homopolymer linear polypropylene with an melt flow index of 18 g/10 min, a high melt flow index coupling agent (G3003, melt flow index of 380 g/min), and different nanoclay (Cloisite 20A) content was investigated. A twin-screw extruder was used to prepare the nanocomposite compounds, and an X-ray diffraction machine was used to characterize the intercalation and exfoliation of nanoclay within the matrix. A rheology test was undertaken to investigate the melt shear viscosity of the samples. A single-screw extruder was employed to produce foam by using 5% supercritical CO2 at various die temperatures. Scanning electron microscopy was used to explore the morphology of the foamed samples, and cell density was calculated by scanning electron microscopy images. Density measurement data was used to calculate the expansion ratio of the foamed samples. Extrusion foaming produced foams with high expansion ratios of about 20 and a high cell density of about 108−9 cells/cm3. The crystallinity behavior of the foamed and unfoamed linear polypropylene and linear polypropylene nanocomposites was also investigated. A high-pressure differential scanning calorimetry was used to investigate the dependency of crystallization behavior on high pressure CO2.