Reusable, Recyclable, and Biodegradable Heat-Shrinkable Melt Cross-Linked Poly(butylene adipate-co-terephthalate)/Pulp Biocomposites for Polyvinyl Chloride Replacement

Heat-shrinkable films are widely used as disposable secondary packaging but are conventionally made from fossil-based and nonbiodegradable polyvinyl chloride or polyethylene. To lower the environmental impact of such products, this work reports the development of recyclable, biodegradable, and partially biosourced heat-shrinkable biocomposites that are cost-competitive with existing shrink wraps. Poly(butylene adipate-co-terephthalate), a growing biodegradable thermoplastic, was simultaneously reinforced with pulp fibers and partially cross-linked in a single-step reactive melt processing. The designed peroxide-initiated reaction led to a 55 wt % cocontinuous insoluble gel incorporating all the pulp fibers into a cross-linked polymer network. In the solid state, the cross-linked biocomposite shows 60% elongation at break with a 200% increase in Young's modulus, while the only addition of pulp fibers stiffens and embrittles the matrix. Creep tests in the melt state indicated that the cross-linked network induces homogeneous shrinking even during the loading phase, demonstrating the potential use of the biocomposites as heat-shrinkable films. The shrinking also promotes the shape-memory of the biocomposite, which retains its dimensions after four cycles. The circularity of the materials was assessed by mechanical recycling and industrial composting, which have proven feasible end-of-life options for heat-shrinkable biocomposites.

Oxidization and Chain-Branching Reaction for Recycling HDPE and Mixed HDPE/PP with In-situ Compatibilization by Ozone-Induced Reactive Extrusion

High-density polyethylene (HDPE) and isotactic polypropylene (iPP) are widely used in industrial and residential applications due to their low cost and chemical stability, thus their recycling process can contribute to a circular economy. However, both polymers are non-polar materials, and the incompatibility with most other materials leads to substantially inferior properties of blends. In this work, we propose a flexible compatibilization strategy to improve the compatibility of HDPE/iPP blends. Ozone is adopted to induce reactive extrusion for rapid oxidation of HDPE and chain-branching reactions for both HDPE and HDPE/iPP blends. During extrusion process, ozone oxidizes HDPE effectively in a short time and introduces oxygen-containing groups such as carbonyl and ester groups, which improves the hydrophilicity. The addition of trimethylolpropane triacrylate (TMPTA) could promote branching reaction and facilitate the formation of HDPE-g-iPP copolymers, which improved the compatibility for HDPE/iPP. As a result, the impact strength of ozone-modified HDPE and HDPE/iPP blends increased by 22 % and 82 %, respectively, and the tensile strength also increased. This strategy would have potential applications in the field of sorting-free and solvent-free recycling of waste polyolefin plastics.

Improvement of the Ductility of Environmentally Friendly Poly(lactide) Composites with Posidonia oceanica Wastes Plasticized with an Ester of Cinnamic Acid

New composite materials were developed with poly(lactide) (PLA) and Posidonia oceanica fibers through reactive extrusion in the presence of dicumyl peroxide (DCP) and subsequent injection molding. The effect of different amounts of methyl trans-cinnamate (MTC) on the mechanical, thermal, thermomechanical, and wettability properties was studied. The results showed that the presence of Posidonia oceanica fibers generated disruptions in the PLA matrix, causing a decrease in the tensile mechanical properties and causing an impact on the strength due to the stress concentration phenomenon. Reactive extrusion with DCP improved the PO/PLA interaction, diminishing the gap between the fibers and the surrounding matrix, as corroborated by field emission scanning electron microscopy (FESEM). It was observed that 20 phr (parts by weight of the MTC, per one hundred parts by weight of the PO/PLA composite) led to a noticeable plasticizing effect, significantly increasing the elongation at break from 7.1% of neat PLA to 31.1%, which means an improvement of 338%. A considerable decrease in the glass transition temperature, from 61.1 °C of neat PLA to 41.6 °C, was also observed. Thermogravimetric analysis (TGA) showed a loss of thermal stability of the plasticized composites, mainly due to the volatility of the cinnamate ester, leading to a decrease in the onset degradation temperature above 10 phr MTC.

Soybean-Based Polyol as a Substitute of Fossil-Based Polyol on the Synthesis of Thermoplastic Polyurethanes: The Effect of Its Content on Morphological and Physicochemical Properties

Thermoplastic polyurethanes (TPUs) are remarkably versatile polymers due to the wide range of raw materials available for their synthesis, resulting in physicochemical characteristics that can be tailored according to the specific requirements of their final applications. In this study, a renewable bio-based polyol obtained from soybean oil is used for the synthesis of TPU via reactive extrusion, and the influence of the bio-based polyol on the multi-phase structure and properties of the TPU is studied. As raw materials, 4,4'-diphenylmethane (MDI), 1,4-butanediol, a fossil-based polyester polyol, and a bio-based polyol are used. The fossil-based to soybean-based polyol ratios studied are 100/0, 99/1, 95/5, 90/10, 80/20, and 50/50% by weight, respectively. The TPUs were characterized by size exclusion chromatography (SEC), gel content analysis, Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), small-angle X-ray scattering (SAXS), dynamic mechanical analysis (DMA), and contact angle measurements. The results reveal that incorporating the renewable polyol enhances the compatibility between the rigid and flexible segments of the TPU. However, due to its high functionality, the addition of soybean-based polyol can promote cross-linking. This phenomenon reduces the density of hydrogen bonds within the material, also reducing polarity and restricting macromolecular mobility, as corroborated by higher glass transition temperature (Tg) values. Remarkably, the addition of small amounts of the bio-based polyol (up to 5 wt.% of the total polyol content) results in high-molecular-weight TPUs with lower polarity, combined with suitable processability and mechanical properties, thus broadening the range of applications and improving their sustainability.

Balancing the Strength-Impact Relationship and Other Key Properties in Polypropylene Copolymer-Natural CaSO4 (Anhydrite)-Filled Composites

To develop novel mineral-filled composites and assess their enhanced properties (stiffness, a good balance between mechanical strength and impact resistance, greater temperature stability), a high-impact polypropylene copolymer (PPc) matrix containing an elastomeric discrete phase was melt mixed with natural CaSO4 β-anhydrite II (AII) produced from gypsum rocks. First, in a prior investigation, the PPc composites filled with AII (without any modification) displayed enhanced stiffness, which is correlated with the relative content of the filler. The tensile and impact strengths dramatically decreased, especially at high filling (40 wt.%). Therefore, two key methods were considered to tune up their properties: (a) the ionomeric modification of PPc composites by reactive extrusion (REx) with zinc diacrylate (ZA), and (b) the melt mixing of PPc with AII surface modified with ethylenebis(stearamide) (EBS), which is a multifunctional processing/dispersant additive. The properties of composites produced with twin-screw extruders (TSEs) were deeply assessed in terms of morphology, mechanical, and thermal performance, including characterizations under dynamic mechanical solicitations at low and high temperatures. Two categories of products with distinct properties are obtained. The ionomeric modification by Rex (evaluated by FTIR) led to composites characterized by remarkable thermal stability, a higher temperature of crystallization, stronger interfacial interactions, and therefore noticeable mechanical properties (high tensile strength (i.e., 28 MPa), increased stiffness, moderate (3.3 kJ/m2) to good (5.0 kJ/m2) impact resistance) as well as advanced heat deflection temperature (HDT). On the other hand, the surface modification of AII with EBS facilitated the dispersion and debonding of microparticles, leading to composites revealing improved ductility (strain at break from 50% to 260%) and enhanced impact properties (4.3-5.3 kJ/m2), even at high filling. Characterized by notable mechanical and thermal performances, high whiteness, and a good processing ability, these new PPc-AII composites may be tailored to meet the requirements of end-use applications, ranging from packaging to automotive components.

Reactive Extrusion of Nonmigratory Active and Intelligent Packaging

The environmental and economic burden of food waste demands new preservation technologies to reduce the degradative actions of spoilage such as moisture, oxygen, and microorganisms. Direct food additives can help maintain product quality; however, the limited life span of these additives combined with consumer desire for "clean label" products has motivated research into new food manufacturing technologies like active and intelligent packaging that can prevent and detect food spoilage. In this work, curcumin was grafted to polypropylene (PP-g-Cur) via reactive extrusion to produce nonmigratory active and intelligent packaging through a solvent-free, efficient, and continuous method. Immobilization of curcumin was confirmed by a standard migration assay exhibiting a maximum of 0.011 mg/cm² migration, significantly below the EU migratory limit for food contact materials (0.1 mg/cm²). Compared to native PP films, PP-g-Cur films blocked 93% of UV light while retaining 64% transparency in the visible region, allowing for desirable product visibility while inhibiting UV degradation of packaged goods. While the ability of PP-g-Cur to inhibit growth of E. coli and L. monocytogenes was insignificant compared to control PP, free curcumin exhibited poor bacterial inhibition as well, suggesting that without hydrophilic modification, native curcumin has limited antimicrobial efficacy. PP-g-Cur films displayed significant radical scavenging in both organic (11.71 ± 3.02 Trolox_Eq (nmol/cm²)) and aqueous (3.18 ± 1.04 Trolox_Eq (nmol/cm²)) matrices, exhibiting potential for antioxidant behavior in both lipophilic and hydrophilic applications. Finally, when PP-g-Cur films were exposed to ammonia, an indicator of microbial growth, the color visually and quantitatively changed from yellow to red, demonstrating potential to indicate spoilage. These findings demonstrate the potential of a scalable technology to produce active and intelligent packaging to limit food waste and advance the capabilities of functional materials in a variety of applications.

Poly(Lactic Acid) Composites with Lignin and Nanolignin Synthesized by In Situ Reactive Processing

Poly(lactic acid) (PLA) composites with 0.5 wt% lignin or nanolignin were prepared with two different techniques: (a) conventional melt-mixing and (b) in situ Ring Opening Polymerization (ROP) by reactive processing. The ROP process was monitored by measuring the torque. The composites were synthesized rapidly using reactive processing that took under 20 min. When the catalyst amount was doubled, the reaction time was reduced to under 15 min. The dispersion, thermal transitions, mechanical properties, antioxidant activity, and optical properties of the resulting PLA-based composites were evaluated with SEM, DSC, nanoindentation, DPPH assay, and DRS spectroscopy. All reactive processing-prepared composites were characterized by means of SEM, GPC, and NMR to assess their morphology, molecular weight, and free lactide content. The benefits of the size reduction of lignin and the use of in situ ROP by reactive processing were demonstrated, as the reactive processing-produced nanolignin-containing composites had superior crystallization, mechanical, and antioxidant properties. These improvements were attributed to the participation of nanolignin in the ROP of lactide as a macroinitiator, resulting in PLA-grafted nanolignin particles that improved its dispersion.

Rheology of Recycled PET

Polyethylene terephthalate (PET) is a thermoplastic material that is widely used in many application fields, such as packaging, construction and household products. Due to the relevant contribution of PET to global yearly solid waste, the recycling of such material has become an important issue. Disposed PET does not maintain the mechanical properties of virgin material, as exposure to water and other substances can cause multiple chain scissions, with subsequent degradation of the viscoelastic properties. For this reason, chain extension is needed to improve the final properties of the recycled product. Chain extension is generally performed through reactive extrusion. As the latter involves structural modification and flow of PET molecules, rheology is a relevant asset for understanding the process and tailoring the mechanical properties of the final products. This paper briefly reviews relevant rheological studies associated with the recycling of polyethylene terephthalate through the reactive extrusion process.

Engineering Polypropylene-Calcium Sulfate (Anhydrite II) Composites: The Key Role of Zinc Ionomers via Reactive Extrusion

Polypropylene (PP) is one of the most versatile polymers widely used in packaging, textiles, automotive, and electrical applications. Melt blending of PP with micro- and/or nano-fillers is a common approach for obtaining specific end-use characteristics and major enhancements of properties. The study aims to develop high-performance composites by filling PP with CaSO₄ β-anhydrite II (AII) issued from natural gypsum. The effects of the addition of up to 40 wt.% AII into PP matrix have been deeply evaluated in terms of morphology, mechanical and thermal properties. The PP-AII composites (without any modifier) as produced with internal mixers showed enhanced thermal stability and stiffness. At high filler loadings (40% AII), there was a significant decrease in tensile strength and impact resistance; therefore, custom formulations with special reactive modifiers/compatibilizers (PP functionalized/grafted with maleic anhydride (PP-g-MA) and zinc diacrylate (ZnDA)) were developed. The study revealed that the addition of only 2% ZnDA (able to induce ionomeric character) leads to PP-AII composites characterized by improved kinetics of crystallization, remarkable thermal stability, and enhanced mechanical properties, i.e., high tensile strength, rigidity, and even rise in impact resistance. The formation of Zn ionomers and dynamic ionic crosslinks, finer dispersion of AII microparticles, and better compatibility within the polyolefinic matrix allow us to explain the recorded increase in properties. Interestingly, the PP-AII composites also exhibited significant improvements in the elastic behavior under dynamic mechanical stress and of the heat deflection temperature (HDT), thus paving the way for engineering applications. Larger experimental trials have been conducted to produce the most promising composite materials by reactive extrusion (REx) on twin-screw extruders, while evaluating their performances through various methods of analysis and processing.

Improvement of the Thermal Stability of Polymer Bioblends by Means of Reactive Extrusion

Poly(lactic acid) (PLA) and biosourced polyamide (PA) bioblends, with a variable PA weight content of 10-50%, were manufactured by melt blending in order to improve the behavior of PLA against thermal degradation. The effect of reactive extrusion on the thermal performance of PLA within bioblends was analyzed. The reactive extrusion was made by means of the addition of a styrene-acrylic multi-functional-epoxide oligomeric reactive agent (SAmfE), with the commercial name of Joncryl. Four parameters were considered in order to study the thermal behavior of bioblends against thermal decomposition: the onset decomposition temperature, the shape and temperature interval of the thermal decomposition patterns, the activation energy of the thermal decomposition, and the evidence leading to the most probable mechanism. The latter was determined by means of three evidence: standardized conversion functions, y(α) master plots, and integral mean error. It was shown that reactive extrusion of PLA as well as PA incorporation to the polymer matrix of PLA were responsible for an increase in the onset decomposition temperature of 10.4 °C. The general analytical equation (GAE) was used to evaluate the kinetic parameters of the thermal degradation of PLA within bioblends for various reaction mechanisms. It was shown that the random scission of macromolecular chains is the best mechanism for both untreated and treated PLA by means of reactive extrusion. It was shown that reactive extrusion together with higher content of PA resulted in an increased protective effect against the thermal degradation of PLA as demonstrated by an increase in activation energy of 60 kJ/mol. It was found that there is a relationship between the increase in activation energy and the increase in the onset decomposition temperature when using reactive extrusion. The improvement of the thermal stability of bioblends by means of reactive extrusion was explained by an increase in the complex viscosity from 980 to 2000 Pa·s at 0.06 rad/s and from 250 to 300 Pa·s at 630 rad/s for bioblend containing 30% of PLA_REX and by a finer dispersion of PA within the PLA_REX matrix. Results from DSC were not conclusive regarding the compatibility between both phases.

Upcycling of Poly(Lactic Acid) by Reactive Extrusion with Recycled Polycarbonate: Morphological and Mechanical Properties of Blends

Poly(lactic acid) (PLA) is one of the most promising renewable polymers to be employed to foster ecological and renewable materials in many fields of application. To develop high-performance products, however, the thermal resistance and the impact properties should be improved. At the same time, it is also necessary to consider the end of life through the exploration of property assessment, following reprocessing. In this context the aim of the paper is to develop PLA/PC blends, obtained from recycled materials, in particular scraps from secondary processing, to close the recycling loop. Indeed, the blending of PLA with polycarbonate (PC) was demonstrated to be a successful strategy to improve thermomechanical properties that happens after several work cycles. The correlation between the compositions and properties was then investigated by considering the morphology of the blends; in addition, the reactive extrusions resulting in the formation of a PLA-PC co-polymer were investigated. The materials obtained are then examined by means of a dynamic-mechanical analysis (DMTA) to study the relaxations and transitions.

Impact-Resistant Poly(3-Hydroxybutyrate)/Poly(ε-Caprolactone)-Based Materials, through Reactive Melt Processing, for Compression-Molding and 3D-Printing Applications

Biobased and biocompatible polymers, such as polyhydroxyalkanoates (PHAs), are of great interest for a large range of applications in the spirit of green chemistry and upcoming reuse and recycling strategies. Polyhydroxybutyrate (PHB), as a promising biocompatible polymer belonging to PHAs, is subject to increased research concern regarding the high degree of crystallinity and brittle behavior of the resulting materials. Therefore, the improvement of PHB's physico-mechanical properties aims to decrease the Young's modulus values and to increase the ductility of samples. Here, we proposed an ambitious approach to develop melt-processed materials, while combining PHB characteristics with the ductile properties of poly(ε-caprolactone) (PCL). In order to compatibilize the poorly miscible PHB/PCL blends, dicumyl peroxide (DCP) was used as a free-radical promotor of polyester interchain reactions via the reaction extrusion process. The resulting PHB/PCL-DCP materials revealed a slight increase in the elongation at break, and significant improvement in the impact resistance (7.2 kJ.m^-2) as compared to PHB. Additional decrease in the Young's modulus values was achieved by incorporating low molecular polyethylene glycol (PEG) as a plasticizer, leading to an important improvement in the impact resistance (15 kJ.m^-2). Successful 3D printing using fused deposition melting (FDM) of the resulting PHB/PCL-based blends for the design of a prosthetic finger demonstrated the great potential of the proposed approach for the development of next-generation biomaterials.

Food extrusion: An advanced process for innovation and novel product development

Extrusion is a versatile process capable of producing a variety of new and novel foods and ingredients, thus increasing manufacturing opportunities. Further, it could provide nutritious, safe, sustainable, and affordable foods, especially directed at individualized consumer needs. In addition to past research efforts, more investigations should be conducted in order to refine, redesign, or develop new extrusion processing technologies. The present review highlights the current advances made in new and novel food product development by considering the extrusion process, the influencing parameters, and product characteristics and properties; the most promising extrusion processes that can be used in novel food product and ingredient development, such as extrusion cooking, hot-melt extrusion, reactive extrusion, and extrusion-based 3D printing; the possibilities of using various raw materials in relation to process and product development; and the needs for product development modeling along with extrusion process design and modeling. In correlation with extruded product development, topics that merit further investigation may include structure formation, plant and animal biopolymers functionalization, biopolymer reactions, process simulation, modeling and control, engineering and mechanical aspects of extruders, analysis of pre-processing treatments, as well as prototyping, risk analysis, safety, sensory and consumer acceptance.

Reactive Extrusion as a Pretreatment in Cassava (Manihot esculenta Crantz) and Pea (Pisum sativum L.) Starches to Improve Spinnability Properties for Obtaining Fibers

Starch is a biocompatible and economical biopolymer in which interest has been shown in obtaining electrospun fibers. This research reports that cassava (CEX) and pea (PEX) starches pretreated by means of reactive extrusion (REX) improved the starches rheological properties and the availability of amylose to obtain fibers. Solutions of CEX and PEX (30-36% w/v) in 38% v/v formic acid were prepared and the rheological properties and electrospinability were studied. The rheological values indicated that to obtain continuous fibers without beads, the entanglement concentration (Ce) must be 1.20 and 1.25 times the concentration of CEX and PEX, respectively. In CEX, a higher amylose content and lower viscosity were obtained than in PEX, which resulted in a greater range of concentrations (32-36% w/v) to obtain continuous fibers without beads with average diameters ranging from 316 ± 65 nm to 394 ± 102 nm. In PEX, continuous fibers without beads were obtained only at 34% w/v with an average diameter of 170 ± 49 nm. This study showed that starches (20-35% amylose) pretreated through REX exhibited electrospinning properties to obtain fibers, opening the opportunity to expand their use in food, environmental, biosensor, and biomedical applications, as vehicles for the administration of bioactive compounds.

Reactive Extrusion Synthesis of Biobased Isocyanate-Free Hydrophobically Modified Ethoxylated Urethanes with Pendant Hydrophobic Groups

Development of hydrophobically modified ethoxylated urethane (HEUR) rheology modifiers enabled the widespread application of waterborne paints and coatings, replacing their environmentally burdening solvent-based predecessors. However, the diisocyanates, required for the conventional synthesis of HEURs, pose severe eco-sustainability threats. In this paper, we demonstrate an innovative approach to avoiding toxic components in the preparation of rheology modifiers by obtaining a new class of water-soluble isocyanate-free hydrophobically modified ethoxylated poly(hydroxy-urethane)s (IFHEURs). The first step in the synthetic pathway was the preparation of CO₂-based five-membered poly(ethylene glycol) bis(cyclic carbonate) and its subsequent aminolysis using 4,7,10-trioxa-1,13-tridecanediamine, yielding poly(hydroxy-urethane) (PHU) prepolymers terminated with cyclic carbonate groups. The PHU prepolymers were further extended in a reactive extrusion (REX) synthesis using biobased hydrophobic diamine PRIAMINE 1075. The REX technique made it possible to overcome the typical limitations of the aminolysis reaction and to reach the desired conversion within a moderate reaction time. IFHEURs have been structurally elucidated using FT-IR and NMR spectroscopy techniques, MALDI-ToF mass spectrometry, and SEC analysis and applied as rheology modifiers. The study of their associative behavior in aqueous solutions confirmed that the architectural flexibility of the obtained IFHEURs, containing terminal and pendant hydrophobic groups, opens a perspective for tuneable thickening performance.

Tuning Thermal, Morphological, and Physicochemical Properties of Thermoplastic Polyurethanes (TPUs) by the 1,4-Butanediol (BDO)/Dipropylene Glycol (DPG) Ratio

Thermoplastic polyurethanes (TPUs) are versatile polymers presenting a broad range of properties as a result of their countless combination of raw materials—in essence, isocyanates, polyols, and chain extenders. This study highlights the effect of two different chain extenders and their combination on the structure−property relationships of TPUs synthesized by reactive extrusion. The TPUs were obtained from 4,4-diphenylmethane diisocyanate (MDI), polyester diols, and the chain extenders 1,4-butanediol (BDO) and dipropylene glycol (DPG). The BDO/DPG ratios studied were 100/0, 75/25, 50/50, 25/75, and 0/100 wt.%. The TPUs were characterized by size exclusion chromatography (SEC), Fourier-transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), small-angle X-ray scattering (SAXS), UV−vis spectroscopy, and physical-mechanical properties. The results indicate that DPG promotes compatibility between rigid (HS) and flexible (SS) segments of TPUs. Consequently, increasing DPG content (>75 wt.%) reduced the organization of the rigid segments and the degree of phase separation, increasing the polydispersity of the interdomain distance and the transparency in the UV−visible spectrum of the TPUs. Furthermore, increasing DPG content also reduced the amount of hydrogen bonds present in the rigid phase, reducing or extinguishing its glass transition temperature (TgHS) and melting temperature (Tm), and increasing the glass transition temperature of the flexible phase (TgSS). Therefore, increasing DPG content leads to a deterioration in mechanical properties and hydrolysis resistance.

Transparent PC/PMMA Blends with Enhanced Mechanical Properties via Reactive Compounding of Functionalized Polymers

Reactive compounding of terminally phenolic OH-functionalized polycarbonate (PC) with epoxy-functionalized polymethylmethacrylate (PMMA) prepared by copolymerization with glycidyl methacrylate was investigated. It was spectroscopically demonstrated that a PC/PMMA copolymer was formed during the melt reaction of the functional groups. Zirconium acetylacetonate could catalytically accelerate this reaction. Correlations of the phenomenological (optical and mechanical) properties with the molecular level and mesoscopic (morphological) structure were discussed. By the investigated reactive compounding process, transparent PC/PMMA blends with two-phase morphologies were obtained in a continuous twin-screw extruder, which, for the first time, combined the high transmission of visible light with excellent mechanical performance (e.g., synergistically improved tensile and flexural strength and high scratch resistance). The transparency strongly depended on (a) the degree of functionalization in both PC and PMMA, (b) the presence of the catalyst, and (c) the residence time of the compounding process. The in-situ-formed PC/PMMA copolymer influenced the observed macroscopic properties by (a) a decrease in the interphase tension, leading to improved and stabilized phase dispersion, (b) the formation of a continuous gradient of the polymer composition and thus of the optical refractive indices in a diffuse mesoscopic interphase layer separating the PC and PMMA phases, and (c) an increase in the phase adhesion between PC and PMMA due to mechanical polymer chain entanglement in this interphase.

Synthesis, Properties, and Enzymatic Hydrolysis of Poly(lactic acid)-co-Poly(propylene adipate) Block Copolymers Prepared by Reactive Extrusion

Poly(lactic acid) (PLA) is a biobased polyester with ever-growing applications in the fields of packaging and medicine. Despite its popularity, it suffers from inherent brittleness, a very slow degradation rate and a high production cost. To tune the properties of PLA, block copolymers with poly(propylene adipate) (PPAd) prepolymer were prepared by polymerizing L-lactide and PPAd oligomers via reactive extrusion (REX) in a torque rheometer. The effect of reaction temperature and composition on the molecular weight, chemical structure, and physicochemical properties of the copolymers was studied. The introduction of PPAd successfully increased the elongation and the biodegradation rate of PLA. REX is an efficient and economical alternative method for the fast and continuous synthesis of PLA-based copolymers with tunable properties.

Solvent-Free Design of Biobased Non-isocyanate Polyurethanes with Ferroelectric Properties

Increasing energy autonomy and lowering dependence on lithium-based batteries are more and more appealing to meet our current and future needs of energy-demanding applications such as data acquisition, storage, and communication. In this respect, energy harvesting solutions from ambient sources represent a relevant solution by unravelling these challenges and giving access to an unlimited source of portable/renewable energy. Despite more than five decades of intensive study, most of these energy harvesting solutions are exclusively designed from ferroelectric ceramics such as Pb(Zr,Ti)O3 and/or ferroelectric polymers such as polyvinylidene fluoride and its related copolymers, but the large implementation of these piezoelectric materials into these technologies is environmentally problematic, related with elevated toxicity and poor recyclability. In this work, we reveal that fully biobased non-isocyanate polyurethane-based materials could afford a sustainable platform to produce piezoelectric materials of high interest. Interestingly, these non-isocyanate polyurethanes (NIPUs) with ferroelectric properties could be successfully synthesized using a solvent-free reactive extrusion process on the basis of an aminolysis reaction between resorcinol bis-carbonate and different diamine extension agents. Structure-property relationships were established, indicating that the ferroelectric behavior of these NIPUs depends on the nanophase separation inside these materials. These promising results indicate a significant potential for fulfilling the requirements of basic connected sensors equipped with low-power communication technologies.

Structure and Properties of Reactively Extruded Opaque Post-Consumer Recycled PET

The recyclability of opaque PET, which contains TiO₂ nanoparticles, has not been as well-studied as that of transparent PET. The objective of this work is to recycle post-consumer opaque PET through reactive extrusion with Joncryl. The effect of the reactive extrusion process on the molecular structure and on the thermal/mechanical/rheological properties of recycling post-consumer opaque PET (r-PET) has been analyzed. A 1% w/w Joncryl addition caused a moderate increase in the molecular weight. A moderate increase in chain length could not explain a decrease in the overall crystallization rate. This result is probably due to the presence of branches interrupting the crystallizable sequences in reactive extruded r-PET (REX-r-PET). A rheological investigation performed by SAOS/LAOS/elongational studies detected important structural modifications in REX-r-PET with respect to linear r-PET or a reference virgin PET. REX-r-PET is characterized by a slow relaxation process with enlarged elastic behaviors that are characteristic of a long-chain branched material. The mechanical properties of REX-r-PET increased because of the addition of the chain extender without a significant loss of elongation at the break. The reactive extrusion process is a suitable way to recycle opaque PET into a material with enhanced rheological properties (thanks to the production of a chain extension and long-chain branches) with mechanical properties that are comparable to those of a typical virgin PET sample.

Continuous, Large-Scale, and High Proportion of Bioinspired Phosphogypsum Composites via Reactive Extrusion

Biological matter evolution provides an idea for the human design and synthesis of new materials. However, biomimetic materials only stay in laboratory-scale models, and their large-scale industrial applications are yet to be realized. Here, inspired by nacre's architecture, we report a continuous, large-scale method to fabricate phosphogypsum composites by reactive extrusion strategy. After curing for seven days, with more than 50 wt% of beta-hemihydrate phosphogypsum (β-HPG), the compressive strength and softening coefficient were 24.98 MPa and 0.78, increasing by 110.0% and 20.0%, respectively, compared to the pouring method. The results show that the screw extrusion process can improve the mechanical strength and waterproof properties of β-HPG hydration specimens without any special chemical admixtures and cements.

Improved Mechanical, Thermal, and Hydrophobic Properties of PLA Modified with Alkoxysilanes by Reactive Extrusion Process

An eco-friendly strategy for the modification of polylactic acid (PLA) surface properties, using a solvent-free process, is reported. Reactive extrusion (REX) allowed the formation of new covalent bonds between functional molecules and the PLA polymeric matrix, enhancing its mechanical properties and modifying surface hydrophobicity. To this end, the PLA backbone was modified using two alkoxysilanes, phenyltriethoxysilane and N-octyltriethoxysilane. The reactive extrusion process was carried out under mild conditions, using melting temperatures between 150 and 180 °C, 300 rpm as screw speed, and a feeding rate of 3 kg·h⁻¹. To complete the study, flat tapes of neat and functionalized PLA were obtained through monofilament melt extrusion to quantify the enhancement of mechanical properties and hydrophobicity. The results verified that PLA modified with 3 wt% of N-octyltriethoxysilane improves mechanical and thermal properties, reaching Young’s modulus values of 4.8 GPa, and PLA hydrophobic behavior, with values of water contact angle shifting from 68.6° to 82.2°.

Production of Cyclic Anhydride-Modified Starches

Modified starches offer a biodegradable, readily available, and cost-effective alternative to petroleum-based products. The reaction of alkenylsuccinic anhydrides (ASAs), in particular, is an efficient method to produce amphiphilic starches with numerous applications in different areas. While ASAs are typically derived from petroleum sources, maleated soybean oil can also be used in an effort to produce materials from renewable sources. The reaction of gelatinized waxy maize starch with octenylsuccinic anhydride (OSA), dodecenylsuccinic anhydride (DDSA), a maleated fatty acid (TENAX 2010), phthalic anhydride (PA), 1,2,4-benzenetricarboxylic acid anhydride (trimellitic anhydride, TMA), and three maleated soybean oil samples, was investigated under different conditions. To minimize the reaction time and the amount of water required, the outcome of the esterification reaction was compared for starch dispersions in benchtop dispersed reactions, for starch melts in a heated torque rheometer, and for reactive extrusion in a pilot plant scale twin-screw extruder. The extent of reaction was quantified by ¹H NMR analysis, and changes in molecular weight and diameter were monitored by gel permeation chromatography (GPC) analysis. The outcome of the reactions varied markedly in terms of reaction efficiency (RE), molecular weight distribution, and average hydrodynamic diameter, for the products derived from the different maleated reagents used, as well as for the different reaction protocols.

Synthesis of an Addition-Crosslinkable, Silicon-Modified Polyolefin via Reactive Extrusion Monitored by In-Line Raman Spectroscopy

We present the modification of ethylene-propylene rubber (EPM) with vinyltetra-methydisiloxane (VTMDS) via reactive extrusion to create a new silicone-based material with the potential for high-performance applications in the automotive, industrial and biomedical sectors. The radical-initiated modification is achieved with a peroxide catalyst starting the grafting reaction. The preparation process of the VTMDS-grafted EPM was systematically investigated using process analytical technology (in-line Raman spectroscopy) and the statistical design of experiments (DoE). By applying an orthogonal factorial array based on a face-centered central composite experimental design, the identification, quantification and mathematical modeling of the effects of the process factors on the grafting result were undertaken. Based on response surface models, process windows were defined that yield high grafting degrees and good grafting efficiency in terms of grafting agent utilization. To control the grafting process in terms of grafting degree and grafting efficiency, the chemical changes taking place during the modification procedure in the extruder were observed in real-time using a spectroscopic in-line Raman probe which was directly inserted into the extruder. Successful grafting of the EPM was validated in the final product by ¹H-NMR and FTIR spectroscopy.

Improving Rheological and Mechanical Properties of Various Virgin and Recycled Polypropylenes by Blending with Long-Chain Branched Polypropylene

Blends of two long-chain branched polypropylenes (LCB-PP) and five linear polypropylenes (L-PP) were prepared in a single screw extruder at 240 °C. The two LCB-PPs were self-created via reactive extrusion at 180 °C by using dimyristyl peroxydicarbonate (PODIC C126) and dilauroyl peroxide (LP) as peroxides. For blending two virgin and three recycled PPs like coffee caps, yoghurt cups and buckets with different melt flow rate (MFR) values were used. The influence of using blends was assessed by investigating the rheological (dynamic and extensional rheology) and mechanical properties (tensile test and impact tensile test). The dynamic rheology indicated that the molecular weight as well as the molecular weight distribution could be increased or broadened. Also the melt strength behavior could be improved by using the two peroxide modified LCB-PP blends on the basis of PODIC C126 or PEROXAN LP (dilauroyl peroxide). In addition, the mechanical properties were consistently enhanced or at least kept constant compared to the original material. In particular, the impact tensile strength but also the elongation at break could be increased considerably. This study showed that the blending of LCB-PP can increase the investigated properties and represents a promising option, especially when using recycled PP, which demonstrates a real "up-cycling" process.

Compatibilization of Poly(Lactic Acid) (PLA)/Plasticized Cellulose Acetate Extruded Blends through the Addition of Reactively Extruded Comb Copolymers

In the perspective of producing a rigid renewable and environmentally friendly rigid packaging material, two comb-like copolymers of cellulose acetate (AC) and oligo(lactic acid) OLA, feeding different percentages of oligo(lactic acid) segments, were prepared by chemical synthesis in solvent or reactive extrusion in the melt, using a diepoxide as the coupling agent and were used as compatibilizers for poly(lactic acid)/plasticized cellulose acetate PLA/pAC blends. The blends were extruded at 230 °C or 197 °C and a similar compatibilizing behavior was observed for the different compatibilizers. The compatibilizer C1 containing 80 wt% of AC and 14 wt% of OLA resulted effective in compatibilization and it was easily obtained by reactive extrusion. Considering these results, different PLAX/pAC(100-X) compounds containing C1 as the compatibilizer were prepared by extrusion at 197 °C and tested in terms of their tensile and impact properties. Reference materials were the uncompatibilized corresponding blend (PLAX/pAC(100-X)) and the blend of PLA, at the same wt%, with C1. Significant increase in Young’s modulus and tensile strength were observed in the compatibilized blends, in dependence of their morphologic features, suggesting the achievement of an improved interfacial adhesion thanks to the occurred compatibilization.

Development of Toughened Flax Fiber Reinforced Composites. Modification of Poly(lactic acid)/Poly(butylene adipate-co-terephthalate) Blends by Reactive Extrusion Process

The presented study focuses on the development of flax fiber (FF) reinforced composites prepared with the use of poly(lactic acid)/poly(butylene adipate-co-terephthalate)-PLA/PBAT blend system. This type of modification was aimed to increase impact properties of PLA-based composites, which are usually characterized by high brittleness. The PLA/PBAT blends preparation was carried out using melt blending technique, while part of the samples was prepared by reactive extrusion process with the addition of chain extender (CE) in the form of epoxy-functionalized oligomer. The properties of unreinforced blends was evaluated using injection molded samples. The composite samples were prepared by compression molding technique, while flax fibers reinforcement was in the form of plain fabric. The properties of the laminated sheets were investigated during mechanical test measurements (tensile, flexural, impact). Differential scanning calorimetry (DSC) analysis was used to determine the thermal properties, while dynamic mechanical thermal analysis (DMTA) and heat deflection temperature (HDT) measurements were conducted in order to measure the thermomechanical properties. Research procedure was supplemented with structure evaluation using scanning electron microscopy (SEM) analysis. The comparative study reveals that the properties of PLA/PBAT-based composites were more favorable, especially in the context of impact resistance improvement. However, for CE modified samples also the modulus and strength was improved. Structural observations after the impact tests confirmed the presence of the plastic deformation of PLA/PBAT matrix, which confirmed the favorable properties of the developed materials. The use of PBAT phase as the impact modifier strongly reduced the PLA brittleness, while the reactive extrusion process improves the fiber-matrix interactions leading to higher stiffness and strength.

Reactive Extrusion of Maleic-Anhydride-Grafted Polypropylene by Torque Rheometer and Its Application as Compatibilizer

This study is based upon the functionalization of polypropylene (PP) by radical polymerization to optimize its properties by influencing its molecular weight. Grafting of PP was done at different concentrations of maleic anhydride (MAH) and benzoyl peroxide (BPO). The effect on viscosity during and after the reaction was studied by torque rheometer and melt flow index. Results showed that a higher concentration of BPO led to excessive side-chain reactions. At a high percentage of grafting, lower molecular weight product was produced, which was analyzed by viscosity change during and after the reaction. Percentage crystallinity increased by grafting due to the shorter chains, which consequently led to an improvement in the chain's packing. Prepared Maleic anhydride grafted polypropylene (MAH-g-PP) enhanced interactions in PP-PET blends caused a partially homogeneous blend with less voids.

Optimizing the Process Efficiency of Reactive Extrusion in the Synthesis of Vinyltrimethoxysilane-Grafted Ethylene-Octene-Copolymer (EOC-g-VTMS) by Response Surface Methodology

Thermoplastic polymers like ethylene-octene copolymer (EOC) may be grafted with silanes via reactive extrusion to enable subsequent crosslinking for advanced biomaterials manufacture. However, this reactive extrusion process is difficult to control and it is still challenging to reproducibly arrive at well-defined products. Moreover, high grafting degrees require a considerable excess of grafting reagent. A large proportion of the silane passes through the process without reacting and needs to be removed at great expense by subsequent purification. This results in unnecessarily high consumption of chemicals and a rather resource-inefficient process. It is thus desired to be able to define desired grafting degrees with optimum grafting efficiency by means of suitable process control. In this study, the continuous grafting of vinyltrimethoxysilane (VTMS) on ethylene-octene copolymer (EOC) via reactive extrusion was investigated. Successful grafting was verified and quantified by ¹H-NMR spectroscopy. The effects of five process parameters and their synergistic interactions on grafting degree and grafting efficiency were determined using a face-centered experimental design (FCD). Response surface methodology (RSM) was applied to derive a causal process model and define process windows yielding arbitrary grafting degrees between <2 and >5% at a minimum waste of grafting agent. It was found that the reactive extrusion process was strongly influenced by several second-order interaction effects making this process difficult to control. Grafting efficiencies between 75 and 80% can be realized as long as grafting degrees <2% are admitted.

Biodegradable Urea-Formaldehyde/PBS and Its Ternary Nanocomposite Prepared by a Novel and Scalable Reactive Extrusion Process for Slow-Release Applications in Agriculture

Novel binary composite urea-formaldehyde/poly(butylene succinate) (UF/PBS) and its ternary nanocomposite UF/PBS/potassium dihydrogen phosphate (MKP) were prepared by a simple and scalable reactive extrusion approach using methylolurea (MU), PBS, and MKP as the raw materials. The results show that MUs react by melt polycondensation to form UFs with different polymerization degrees at the high temperature in the extruder, giving the two polymer components molecular segment-scale mixing in composites. Meanwhile, MKPs dissolved in the water generated by the melt polycondensation are perfectly confined to the nanometer scale during their precipitation process in ternary composites due to the hydrogen bonding interactions between them and UF and the "cage effect" of UF and PBS macromolecule chains. Both composites have excellent processability, mechanical properties, and slow-release performances. Compared with UF prepared by direct synthesis or reactive extrusion, N release speeds of the two composites are much lower in the early incubation stage but much higher in the subsequent stages; ternary composites can also impart MKP with excellent slow-release properties. This study can provide a good feasibility for large-scale applications of UF-based or PBS-based composites and nanocomposites used as slow-release fertilizers or other products in agriculture or horticulture.

Influence of Different Types of Peroxides on the Long-Chain Branching of PP via Reactive Extrusion

Long-chain branching (LCB) is known as a suitable method to increase the melt strength behavior of linear polypropylene (PP), which is a fundamental weakness of this material. This enables the modification of various properties of PP, which can then be used-in the case of PP recyclates-as a practical "upcycling" method. In this study, the effect of five different peroxides and their effectiveness in building LCB as well as the obtained mechanical properties were studied. A single screw extruder at different temperatures (180 and 240 °C) was used, and long-chain branched polypropylene (PP-LCB) was prepared via reactive extrusion by directly mixing the peroxides. The peroxides used were dimyristyl peroxydicarbonate (PODIC C126), tert-butylperoxy isopropylcarbonate (BIC), tert-Butylperoxy 2-ethylhexyl carbonate (BEC), tert-amylperoxy 2-ethylhexylcarbonate (AEC), and dilauroyl peroxide (LP), all with a concentration of 20 mmol/kg. The influence of the temperature on the competitive prevalent reactions of degradation and branching was documented via melt mass-flow rate (MFR), rheology measurements, and gel permeation chromatography (GPC). However, via extensional rheology, strain hardening could be observed in all cases and the mechanical properties could be maintained or even improved. Particularly, PODIC C126 and LP signaled a promising possibility for LCB in this study.

Evaluation of Different Compatibilization Strategies to Improve the Performance of Injection-Molded Green Composite Pieces Made of Polylactide Reinforced with Short Flaxseed Fibers

Green composites made of polylactide (PLA) and short flaxseed fibers (FFs) at 20 wt % were successfully compounded by twin-screw extrusion (TSE) and subsequently shaped into pieces by injection molding. The linen waste derived FFs were subjected to an alkalization pretreatment to remove impurities, improve the fiber surface quality, and make the fibers more hydrophobic. The alkali-pretreated FFs successfully reinforced PLA, leading to green composite pieces with higher mechanical strength. However, the pieces also showed lower ductility and toughness and the lignocellulosic fibers easily detached during fracture due to the absence or low interfacial adhesion with the biopolyester matrix. Therefore, four different compatibilization strategies were carried out to enhance the fiber-matrix interfacial adhesion. These routes consisted on the silanization of the alkalized FFs with a glycidyl silane, namely (3-glycidyloxypropyl) trimethoxysilane (GPTMS), and the reactive extrusion (REX) with three compatibilizers, namely a multi-functional epoxy-based styrene-acrylic oligomer (ESAO), a random copolymer of poly(styrene-co-glycidyl methacrylate) (PS-co-GMA), and maleinized linseed oil (MLO). The results showed that all the here-tested compatibilizers improved mechanical strength, ductility, and toughness as well as the thermal stability and thermomechanical properties of the green composite pieces. The highest interfacial adhesion was observed in the green composite pieces containing the silanized fibers. Interestingly, PS-co-GMA and, more intensely, ESAO yielded the pieces with the highest mechanical performance due to the higher reactivity of these additives with both composite components and their chain-extension action, whereas MLO led to the most ductile pieces due to its secondary role as plasticizer for PLA.

Compatibilization of Poly(Lactic Acid) (PLA) and Bio-Based Ethylene-Propylene-Diene-Rubber (EPDM) via Reactive Extrusion with Different Coagents

Much effort has been made to enhance the toughness of poly (lactic acid) (PLA) to broaden its possible range of usage in technical applications. In this work, the compatibility of PLA with a partly bio-based ethylene-propylene-diene-rubber (EPDM) through reactive extrusion was investigated. The concentration of EPDM in the PLA matrix was in the range of up to 20%. The reactive extrusion was carried out in a conventional twin-screw extruder. Contact angle measurements were performed to calculate the interfacial tension and thus the compatibility between the phases. The thermal and mechanical properties as well as the phase morphology of the blends were characterized. A copolymer of poly (ethylene-co-methyl acrylate-co-glycidyl methacrylate) (EMAGMA) was used as compatibilizer, which leads to a significant reduction in the particle size of the dispersed rubber phase when compared with the blends without this copolymer. The use of EMAGMA combined with soybean oil (SBO) and a radical initiator enhances the elongation at break of the compound. The results indicate that the reduction of the particle size of the dispersed phase obtained with the compatibilizer alone is not sufficient to improve the mechanical properties of the blend system. The induced radical reactions also influenced the mechanical properties of the blend significantly.

Reactive Extrusion of Nonmigratory Antioxidant Poly(lactic acid) Packaging

Reactive extrusion of bio-derived active packaging offers a new approach to address converging concerns over environmental contamination and food waste. Herein, metal-chelating nitrilotriacetic acid (NTA) ligands were grafted onto poly(lactic acid) (PLA) by reactive extrusion to produce metal-chelating PLA (PLA-g-NTA). Radical grafting was confirmed by attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy with the introduction of secondary alkyl stretches (2919 and 2860 cm^-1) and by X-ray photoelectron spectroscopy (XPS) with an increase in the atomic percentage of nitrogen. Compared to films prepared from native, granular PLA (gPLA), PLA-g-NTA films had lower contact angles and hysteresis values (86.35° ± 2.49 and 31.89° ± 2.27 to 79.91° ± 1.58 and 21.79° ± 1.72, respectively), supporting the surface orientation of the NTA ligands. The PLA-g-NTA films exhibited a significant antioxidant character with a radical scavenging capacity of 0.675 ± 0.026 nmol Trolox_(eq)/cm² and an iron chelation capacity of 54.09 ± 9.36 nmol/cm². PLA-g-NTA films delayed ascorbic acid degradation, retaining ∼45% ascorbic acid over the 9-day study compared to <20% for control PLA. This research makes significant advances in translating active packaging technologies to bio-derived materials using scalable, commercially translatable synthesis methods.

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.

Mechanical Recycling of Partially Bio-Based and Recycled Polyethylene Terephthalate Blends by Reactive Extrusion with Poly(styrene-co-glycidyl methacrylate)

In the present study, partially bio-based polyethylene terephthalate (bio-PET) was melt-mixed at 15-45 wt% with recycled polyethylene terephthalate (r-PET) obtained from remnants of the injection blowing process of contaminant-free food-use bottles. The resultant compounded materials were thereafter shaped into pieces by injection molding for characterization. Poly(styrene-co-glycidyl methacrylate) (PS-co-GMA) was added at 1-5 parts per hundred resin (phr) of polyester blend during the extrusion process to counteract the ductility and toughness reduction that occurred in the bio-PET pieces after the incorporation of r-PET. This random copolymer effectively acted as a chain extender in the polyester blend, resulting in injection-molded pieces with slightly higher mechanical resistance properties and nearly the same ductility and toughness than those of neat bio-PET. In particular, for the polyester blend containing 45 wt% of r-PET, elongation at break (ε_b) increased from 10.8% to 378.8% after the addition of 5 phr of PS-co-GMA, while impact strength also improved from 1.84 kJ·m^-2 to 2.52 kJ·m^-2. The mechanical enhancement attained was related to the formation of branched and larger macromolecules by a mechanism of chain extension based on the reaction of the multiple glycidyl methacrylate (GMA) groups present in PS-co-GMA with the hydroxyl (-OH) and carboxyl (-COOH) terminal groups of both bio-PET and r-PET. Furthermore, all the polyester blend pieces showed thermal and dimensional stabilities similar to those of neat bio-PET, remaining stable up to more than 400 °C. Therefore, the use low contents of the tested multi-functional copolymer can successfully restore the properties of bio-based but non-biodegradable polyesters during melt reprocessing with their recycled petrochemical counterparts and an effective mechanical recycling is achieved.

Plasticization of Polylactide with Myrcene and Limonene as Bio-Based Plasticizers: Conventional vs. Reactive Extrusion

Polylactide (PLA) was blended by conventional and reactive extrusion with limonene (LM) or myrcene (My) as bio-based plasticizers. As-processed blends were carefully analyzed by a multiscale and multidisciplinary approach to tentatively determine their chemical structure, microstructure, thermal properties, tensile and impact behaviors, and hydrothermal stability. The main results indicated that LM and My were efficient plasticizers for PLA, since compared to neat PLA, the glass transition temperature was reduced, the ultimate tensile strain was increased, and the impact strength was increased, independently of the type of extrusion. The addition of a free radical initiator during the extrusion of PLA/LM was beneficial for the mechanical properties. Indeed, the probable formation of local branched/crosslinked regions in the PLA matrix enhanced the matrix crystallinity, the tensile yield stress, and the tensile ultimate stress compared to the non-reactive blend PLA/LM, while the other properties were retained. For PLA/My blends, reactive extrusion was detrimental for the mechanical properties since My polymerization was accelerated resulting in a drop of the tensile ultimate strain and impact strength, and an increase of the glass transition temperature. Indeed, large inclusions of polymerized My were formed, decreasing the available content of My for the plasticization and enhancing cavitation from inclusion-matrix debonding.

Effects of Citric Acid on Structures and Properties of Thermoplastic Hydroxypropyl Amylomaize Starch Films

Hydroxypropyl amylomaize starch (HPAS) films were prepared by hot press. The effects of initial pH of HPAS on the mechanical properties, molecular interaction, structure, and cross-linking degree of the resultant films were investigated. A weak acidic condition was suitable for cross-linking of citric acid and HPAS by reactive extrusion. The film of HPAS with an initial pH of 5.66 had the maximum tensile strength of 7.20 MPa and elongation-at-break of 94.53%, and the weight average molecular weight of HPAS increased to 4.17 × 10⁵ g/mol. An appropriate initial pH facilitated the formation of diester bonds between HPAS and citric acid during extrusion, but too low initial pH levels resulted in hydrolysis of starch molecules and reduced the mechanical properties.

Enhanced Interfacial Adhesion of Polylactide/Poly(ε-caprolactone)/Walnut Shell Flour Composites by Reactive Extrusion with Maleinized Linseed Oil

Novel green composites were prepared by melt compounding a binary blend of polylactide (PLA) and poly(ε-caprolactone) (PCL) at 4/1 (wt/wt) with particles of walnut shell flour (WSF) in the 10–40 wt % range, which were obtained as a waste from the agro-food industry. Maleinized linseed oil (MLO) was added at 5 parts per hundred resin (phr) of composite to counteract the intrinsically low compatibility between the biopolymer blend matrix and the lignocellulosic fillers. Although the incorporation of WSF tended to reduce the mechanical strength and thermal stability of PLA/PCL, the MLO-containing composites filled with up to 20 wt % WSF showed superior ductility and a more balanced thermomechanical response. The morphological analysis revealed that the performance improvement attained was related to a plasticization phenomenon of the biopolymer blend and, more interestingly, to an enhancement of the interfacial adhesion of the green composites achieved by extrusion with the multi-functionalized vegetable oil.

Synergistic Mechanisms Underlie the Peroxide and Coagent Improvement of Natural-Rubber-Toughened Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) Mechanical Performance

Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is a promising bio-based and biodegradable thermoplastic with restricted industrial applications due to its brittleness and poor processability. Natural rubber (NR) has been used as a toughening agent, but further physical improvements are desired. In this study, rubber toughening efficiency was significantly improved through the synergistic use of a trifunctional acrylic coagent and an organic peroxide during reactive extrusion of PHBV and NR. The rheological, crystallization, thermal, morphological, and mechanical properties of PHBV/NR blends with 15% rubber loading were characterized. The peroxide and coagent synergistically crosslinked the rubber phase and grafted PHBV onto rubber backbones, leading to enhanced rubber modulus and cohesive strength as well as improved PHBV⁻rubber compatibility and blend homogeneity. Simultaneously, the peroxide⁻coagent treatment decreased PHBV crystallinity and crystal size and depressed peroxy-radical-caused PHBV degradation. The new PHBV/NR blends had a broader processing window, 75% better toughness (based on the notched impact strength data), and 100% better ductility (based on the tensile elongation data) than pristine PHBV. This new rubber-toughened PHBV material has balanced mechanical performance comparable to that of conventional thermoplastics and is suitable for a wide range of plastic applications.

Facile and Low Environmental Impact Approach to Prepare Thermally Conductive Nanocomposites Based on Polylactide and Graphite Nanoplatelets

In this work, the preparation of nanocomposites based on poly(l-lactide) PLLA and graphite nanoplatelets (GNP) was assessed by applying, for the first time, the reactive extrusion (REX) polymerization approach, which is considered a low environmental impact method to prepare polymer systems and which allows an easy scalability. In particular, ad hoc synthesized molecules, constituted by a pyrene end group and a poly(d-lactide) (PDLA) chain (Pyr-d), capable of interacting with the surface of GNP layers as well as forming stereoblocks during the ring-opening polymerization (ROP) of l-lactide, were used. The nanocomposites were synthesized by adding to l-lactide the GNP/initiator system, prepared by dispersing the graphite in the acetone/Pyr-d solution, which was dried after the sonication process. DSC and X-ray diffraction measurements evidenced the stereocomplexation of the systems synthesized by using the pyrene-based initiators, whose extent turned out to depend on the PDLA chain length. All the prepared nanocomposites, including those synthesized starting from a classical initiator, that is, 1-dodecanol, retained similar electrical conductivity, whereas the thermal conductivity was found to increase in the stereocomplexed samples. Preferential localization of stereocomplexed PLA close to the interface with GNP was demonstrated by scanning probe microscopy (SPM) techniques, supporting an important role of local crystallinity in the thermal conductivity of the nanocomposites.

Biocomposites Based on Poly(3-Hydroxybutyrate-co-3-Hydroxyvalerate) (PHBHV) and Miscanthus giganteus Fibers with Improved Fiber/Matrix Interface

In this paper, green biocomposites based on poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBHV) and Miscanthus giganteus fibers (MIS) were prepared in the presence of dicumyl peroxide (DCP) via reactive extrusion. The objective of this study was to optimize the interfacial adhesion between the reinforcement and the matrix, improving the mechanical properties of the final material. To this aim, two fibers mass fractions (5 and 20 wt %) and two different fiber sizes obtained by two opening mesh sieves (1 mm and 45 μm) were investigated. The impregnation of fibers with DCP before processing was carried out in order to promote the PHBHV grafting onto MIS fibers during the process, favoring, in this way, the interfacial adhesion between fibers and matrix, instead of the crosslinking of the matrix. All composites were realized by extrusion and injection molding processing and then characterized by tensile tests, FTIR-ATR, SEM, DSC and XRD. According to the improved adhesion of fibers to matrix due to DCP, we carried out an implementation of models involving that can predict the effective mechanical properties of the biocomposites. Three phases were taken into account here: fibers, gel (crosslinked matrix), and matrix fractions. Due to the complexity of the system (matrix–crosslinked matrix–fibers) and to the lack of knowledge about all the phenomena occurring during the reactive extrusion, a mathematical approach was considered in order to obtain information about the modulus of the crosslinked matrix and its fraction in the composites. This study aims to estimate these last values, and to clarify the effect caused by the presence of vegetal fibers in a composite in which different reactions are promoted by DCP.

Modelling and Validation of Synthesis of Poly Lactic Acid Using an Alternative Energy Source through a Continuous Reactive Extrusion Process

PLA is one of the most promising bio-compostable and bio-degradable thermoplastic polymers made from renewable sources. PLA is generally produced by ring opening polymerization (ROP) of lactide using the metallic/bimetallic catalyst (Sn, Zn, and Al) or other organic catalysts in a suitable solvent. In this work, reactive extrusion experiments using stannous octoate Sn(Oct)₂ and tri-phenyl phosphine (PPh)₃ were considered to perform ROP of lactide. Ultrasound energy source was used for activating and/or boosting the polymerization as an alternative energy (AE) source. Ludovic^® software, designed for simulation of the extrusion process, had to be modified in order to simulate the reactive extrusion of lactide and for the application of an AE source in an extruder. A mathematical model for the ROP of lactide reaction was developed to estimate the kinetics of the polymerization process. The isothermal curves generated through this model were then used by Ludovic software to simulate the “reactive” extrusion process of ROP of lactide. Results from the experiments and simulations were compared to validate the simulation methodology. It was observed that the application of an AE source boosts the polymerization of lactide monomers. However, it was also observed that the predicted residence time was shorter than the experimental one. There is potentially a case for reducing the residence time distribution (RTD) in Ludovic^® due to the ‘liquid’ monomer flow in the extruder. Although this change in parameters resulted in validation of the simulation, it was concluded that further research is needed to validate this assumption.

Rheological, Morphological and Mechanical Studies of Sustainably Sourced Polymer Blends Based on Poly(Lactic Acid) and Polyamide 11

The objective of this study was to gain a deep understanding of composition and compatibilization effects on the properties of entirely sustainably sourced polymer blends based on polylactide (PLA) and polyamide 11 (PA11). Generally, PLA cannot challenge regular commodity polymers due to its weak thermo-mechanical properties and its poor elongation properties. With this work, however, we present a promising route to overcome these drawbacks in order to enhance the processability of PLA: blending the polymer with various compositions of other ductile biopolymers such as PA11, as well as mixing PLA/PA11 blends with various amounts of a chain extender, Joncryl ADR^®-4368, containing reactive epoxy functions, in a laboratory-scale twin-screw extruder. The effects on the rheological, morphological and mechanical properties were investigated. Results showed that a "self compatibilization" between PLA and PA11 chains can occur but it was found to be insufficient, contrary to recent work reported in the literature. The role of Joncryl as a compatibilizer for the PLA/PA11 system has been demonstrated by the significant decrease of particle size and interfacial tension as well as the improvement of ductile properties. Moreover, a new relaxation peak appeared in the relaxation spectrum, indicating the generation of a copolymer at the polymer-polymer interface.