Optimizing crystallinity of engineered poly(lactic acid)/poly(butylene succinate) blends: The role of single and multiple nucleating agents

This work deals with the design and experimental development of formulations based on bioplastic materials optimized for the production processes of high-performance packaging products, suitable for food contact and characterized by high thermo-mechanical stability. For this purpose, mixtures of poly (L-lactic acid) (PLLA)/poly (butylene succinate) (PBS) (PLA/PBS) containing micro-lamellar talc as reinforcing agent and inorganic nucleating agent have been obtained on a pre-industrial scale. Through the addition in formulation of two organic nucleating agents, ethylene (bis)stereamide (EBS) and poly (D-lactic acid) (PDLA), evaluated separately and in combination with each other, four different PLA/PBS formulations were produced by means of a co-rotating twin screw extruder. The effects on the crystallinity of the materials obtained first in the form of pre-dried pellets, then in the form of films by casting extrusion and, finally, as thermoformed items were compared, according to the variation of the chosen nucleation system. The effect on the crystallinity of the materials was assessed by differential scanning calorimetry (DSC) and by Fourier transform infrared analysis in attenuated total reflection mode (ATR-FTIR). This approach aims to provide data for the further investigation on the processability and the thermo-mechanical properties of end-goods achievable by converting processes (melt processing) of the bioplastic compounds.     

Talc reinforcement of polylactide and biodegradable polyester blends via injection-molding and pilot-scale film extrusion

As a renewable and biodegradable polymer, polylactide (PLA) has taken a foothold in the packaging industry. However, the thermomechanical and barrier properties of PLA-based films need to be improved to facilitate a wider adoption. To address this challenge, we examined the effect of talc reinforcement in composites based on PLA and a biodegradable polyester. Masterbatches of the polymers and talc were produced by melt compounding and processed by either injection-molding or film extrusion in a pilot-scale unit operating at 60–80 m/min. The effect of talc was investigated in relation to the morphological, thermal, mechanical, and barrier properties of the composites. Based on SEM-imaging, talc was found to increase the miscibility of PLA and the polyester while acting as a nucleating agent that improved PLA crystallinity. While this effect did not track with an increased mechanical strength, the composites with 3–4 wt% talc displayed a significantly higher barrier to water vapor. Compared to the neat polymer films, a reduction of water vapor transmission rate, by ~34–37%, was observed at 23°C/50% RH. Meanwhile, the systems loaded with 1 wt% talc showed a reduction in oxygen transmission rates, by up to 34%. Our results highlight the challenges and prospects of commercial PLA-based blends filled with talc from films extruded in pilot-scale units.     

Recycling of PLA-based bioplastics: The role of chain-extenders in twin-screw extrusion compounding and cast extrusion of sheets

Poly (lactic acid) polymers (PLA) belong to the bioplastic family of polymers entirely derived from renewable resources. Among biopolymers, PLA is one of the most technologically interesting materials, thanks to its good mechanical properties and to its moderate thermal stability. There are many fields of application in which the use of PLA seems to be promising, including cast extrusion and thermoforming. However, the strong tendency of PLA to degrade compromises the possibility of recovering the so-called post-process material (i.e., process waste), making PLA and most bioplastics difficult to use in production processes that require a physiological reuse of post-process material, such as the thermoforming process, where huge amounts of scrap material is naturally produced during the trimming phase. In this context, the present study examines the effect of three successive compounding processes by twin-screw reactive extrusion on the rheological and thermal properties of two formulations of compostable bioplastic materials based on PLA, in the presence of a chain extender additive. Subsequently, virgin compounds and post-process material were mixed and cast extruded into slabs. The slabs were then characterized to evaluate their rheological, thermal, and mechanical properties. Finally, the effect of the chain extender was evaluated by adding the additive directly during the cast extrusion of slabs made with 100% post-process material. The results showed that the twin-screw compounding process induces a lower degradation in the material compared to the cast extrusion process. Furthermore, experimental findings show that adding the chain extender during the cast extrusion process of the slabs proved to be an effective post-process material recovery strategy.     

Modification and extrusion coating of polylactic acid films

Polyethylene (PE) extrusion coating on paper substrates are the traditional packing material for coffee cups and take‐out food containers. It is difficult to recycle the PE/paper laminates and the thin polymer films remain in landfills after the decomposition of their paper substrates. Disposal of plastic materials is causing serious effects on our environment and wildlife. Demand for compostable or biodegradable plastic packaging products is increasing because of consumer pressure and legislation. Biodegradable polylactic acid (PLA) is regarded as one of the most promising biopolymers with a large market potential, but its applications are limited by poor thermal stability, mechanical properties and processibility. We utilize modified gelatin as additives to improve PLA's performance without compromizing the biomass origin and compostable properties of the material. Extrusion coating, or extrusion casting, of polylactic acid (PLA) films onto paper substrates to form PLA/paper laminates was achieved by modification of the polymer with a plant or animal gelatin. Various paper substrates with thin PLA coatings were prepared using a conventional extrusion coating equipment for the fabrication of take‐out food containers and coffee cups. Melt rheology of PLA and adhesion of the resulting thin film were greatly improved in the presence of a small amount of gelatin in the polymer matrices. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42472.     

Combined effect of nucleating agent and plasticizer on the crystallization behaviour of polylactide

Different plasticized and nucleated polylactide (PLA) systems were prepared and characterized. Two PLA with different l-lactic acid contents (96 and 99.5%) were plasticized with dioctyl adipate (DOA) and nucleated by talc, ethylene bis(stearamide) (EBS), or d-lactic acid-based PLA (PDLA). Crystallization behaviour was studied by differential scanning calorimetry (DSC), wide-angle X-ray diffraction (WAXD), and polarized optical microscopy (POM). The combination of plasticizer and nucleating agent was proved to be a very effective approach to improve crystallization velocity of different PLA matrices. Within the studied crystallization temperature range, faster crystallization rates were achieved at lower temperatures. WAXS results indicated the coexistence of α and α′ crystals in all studied systems, except those which showed very low crystallization degrees. Avrami exponent remained constant at around n ≈ 3 for all systems, suggesting equivalent three-dimensional spherulitic growth behaviour regardless crystallization temperature, nucleating agent, and the stereochemistry of the matrix used. Usually, injection-moulding process, where molten polymer is under high pressure, is used for PLA polymer processing. To analyze the effect of pressure on the crystallization process, pressure volume temperature (PVT) measurements were carried out on the systems that showed the fastest crystallization process under atmospheric pressure by DSC. Results showed that the crystallization process was considerably accelerated under pressure.     

Challenge to fortyfold expansion of biodegradable polyester foams by using carbon dioxide as a blowing agent

This paper presents a new foaming technology using supercritical carbon dioxide as a blowing agent to obtain large volume expansions of biodegradable polyester foams of over fortyfold. The basic approach for the promotion of a large volume expansion ratio with carbon dioxide was to prevent cell coalescence by using a branched material, to dissolve carbon dioxide completely in the melt by promoting convective diffusion under a high processing pressure, to reduce the diffusivity of gas by lowering the melt temperature, and to optimize the processing conditions in the die to maximize volume expansion. The desirable composition of the materials includes dehydrated branched biodegradable polyester (polybutylene succinate), CO₂ (blowing agent), and tale (nucleating agent). A single‐screw extrusion system was used for foam processing. A large volume expansion ratio of up to forty‐fivefold was achieved from the biodegradable polyester foams. The morphologies and volume expansion ratios of biodegradable polyester foams at various processing temperatures and pressures were studied.     

Effect of biobased and biodegradable nucleating agent on the isothermal crystallization of poly(lactic acid)

The effect of chemically modified thermoplastic starch (CMPS) on the thermal properties and isothermal crystallization kinetics of poly(lactic acid) (PLA) was studied by differential scanning calorimetry (DSC) and compared to that of granular starch and an inorganic nucleating agent, talc. Nucleated PLA showed an additional crystallization of PLA, which affected the melting temperature. The crystallinity and crystallization rate of PLA were considerably enhanced by addition of CMPS, even at 0.1% content, and the amount of the CMPS had little effect on the thermal properties and isothermal crystallization kinetics of PLA. The effect of CMPS as a nucleating agent was comparable to that of granular starch but slightly less than that of talc. However, CMPS can offer a fully biodegradable nucleating agent with no residues remaining for the biobased and biodegradable polymers.     

成核剂TMC-328及TMC-300对聚乳酸结晶性能的影响

通过考察市售的成核剂品种TMC-328与TMC-300对聚乳酸结晶的影响发现,这两种成核剂对聚乳酸结晶均有促进作用,对聚乳酸的抗冲击性也均有提高。     

New insight into the mechanism of enhanced crystallization of PLA in PLLA/PDLA mixture

Poly(lactic acid) (PLA) is a bio‐based and compostable polymer that has quickly developed into a competitive material, but the control of crystallinity is a bottleneck in extended utilization. The crystallization of PLA has been a rich topic because of the existence of two enantiomeric forms of poly(L‐lactic acid) (PLLA) and poly(d ‐lactic acid) (PDLA) can form stereocomplex (SC) crystal with high melting point that can be used to control the crystallization behaviors. The SC crystal was regarded as an effective nucleating agent for promoting the crystallization rate and crystallinity of PLA. We investigated cold crystallization of PLLA/PDLA (1:1) mixture with in situ WAXS measurements and found that the homo‐crystal of PLA formed earlier than the SC‐crystal in the mixture within the measured temperature range, which is different from the melting crystallization. The final crystalline structures are in correspondence with the melting and cold crystallization temperature, and the transition of homo‐PLA (δ to α) is not altered by the crystallization procedure. The SC‐crystal can be detected in both cold and melting crystallization of the mixture at the temperatures lower than 150 °C, which is conflict with the reported results. A new crystallization mechanism of the mixture was proposed to understand the crystallization behaviors in PLLA/PDLA mixtures. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 45663.     

The influence of nucleating agents on the extrusion and thermoforming of polypropylene

A large proportion of thin-gauge containers for the food packaging sector is produced via the thermoforming of extruded thermoplastic sheet (1–4). The production of high quality thermoformed parts is critically dependent on the standard of extruded sheet feedstock used. One method of optimizing the properties of extruded sheet and those of the final thermoformed article is through the incorporation of nucleating agents (5–10). This paper discusses the influence of nucleating agents on the extrusion and thermoforming characteristics of polypropylene. The potential of white titanium dioxide pigment particles as a viable nucleation source for polypropylene is addressed. Evidence is also presented that suggests that nucleating agents may play an important role in controlling the extent of physical change taking place in extruded sheet as a direct result of post-production aging.     

Improving mechanical performance of injection molded PLA by controlling crystallinity

Currently, use of poly(lactic acid) (PLA) for injection molded articles is limited for commercial applications because PLA has a slow crystallization rate when compared with many other thermoplastics as well as standard injection molding cycle times. The overall crystallization rate and final crystallinity of PLA were controlled by the addition of physical nucleating agents as well as optimization of injection molding processing conditions. Talc and ethylene bis‐stearamide (EBS) nucleating agents both showed dramatic increases in crystallization rate and final crystalline content as indicated by isothermal and nonisothermal crystallization measurements. Isothermal crystallization half‐times were found to decrease nearly 65‐fold by the addition of only 2% talc. Process changes also had a significant effect on the final crystallinity of molded neat PLA, which was shown to increase from 5 to 42%. The combination of nucleating agents and process optimization not only resulted in an increase in final injection molded crystallinity level, but also allowed for a decreased processing time. An increase of over 30°C in the heat distortion temperature and improved strength and modulus by upwards of 25% were achieved through these material and process changes. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Association between plasticized starch and polyesters: Processing and performances of injected biodegradable systems

Different formulations of wheat thermoplastic starch (TPS) have been processed with various plasticizer/starch ratios and moisture contents. The biodegradable polyesters tested are polycaprolactone (PCL), polyester amide (PEA), polybutylene succinate adipate (PBSA) and polybutylene adipate co terephtalate (PBAT). TPS and polyesters are melt blended in different proportions by extrusion and then injected to obtain dumbbell specimens. Various properties are evaluated such as the mechanical properties (tensile and impact tests), and the hydrophilic character with contact angle measurements. Additionally, uniaxial shrinkage is evaluated. Results show that the addition of polyester to TPS increases the dimensional post‐injection stability. Blend modulus values are close to the results of the classical rule of mixture. Elongation at break, resilience values and SEM observations seem to give some indications about the compatibility between both polymeric systems. PBAT and PEA present better results than PCL and PBSA. Contact angle measurement show that we have a drastic increase of the hydrophobic character from 10% of polyester in the blend. The different combinations of TPS and polyesters give a wide range of mechanical behavior for compostable materials, to be developed in specific applications.     

Non‐Isothermal Crystallization Behavior of Poly(L‐lactic acid) in the Presence of Various Additives

Summary: The effects of various additives: poly(D ‐lactic acid) (PDLA), talc, fullerene C₆₀, montmorillonite, and various polysaccharides, on the non‐isothermal crystallization behavior of poly(L ‐lactic acid) (PLLA), during both the heating of melt‐quenched films from room temperature, and the cooling of as‐cast films from the melt, was investigated. When the melt‐quenched PLLA films were heated from room temperature, the overall PLLA crystallization was accelerated upon addition of PDLA or the stereocomplex crystallites formed between PDLA and PLLA, the mixtures containing PDLA, and the mixture of talc and montmorillonite. No significant effects on the overall PLLA crystallization were observed for talc, C₆₀, montmorillonite, and the mixtures containing C₆₀. Such rapid completion of the overall PLLA crystallization upon addition of the aforementioned additives can be ascribed to the increased density (number per unit volume or area) of PLLA spherulites. When the as‐cast PLLA films were cooled from the melt, the overall PLLA crystallization completed rapidly, upon addition of PDLA, talc, C₆₀, montmorillonite, and their mixtures. Such rapid overall PLLA crystallization is attributable to the increased density of the PLLA spherulites and the higher nucleation temperature for PLLA crystallization. In contrast, the addition of various polysaccharides has no significant effect, or only a very small effect, on the overall PLLA crystallization during heating from room temperature or during cooling from the melt. This finding means that the polysaccharides can be utilized as low‐cost fillers for PLLA‐based materials, without disturbing the crystallization of the PLLA. The effect of additives in accelerating the overall PLLA crystallization during cooling from the melt, decreased in the following order: PDLA > talc > C₆₀ > montmorillonite > polysaccharides.

Polarization optical photomicrographs of pure PLLA, and the PLLA‐F film, with the fullerene additive, during cooling from the melt (Process IIB). Both of the photomicrographs were taken at 120 °C.     

Melt preparation and nucleation efficiency of polylactide stereocomplex crystallites

A melt blending procedure was developed for the preparation of poly(l-lactide) (PLLA)/poly(d-lactide) (PDLA) stereocomplex crystallites dispersed in a PLLA matrix. All PLLA/PDLA blends were prepared in a batch melt mixer with ≥95% PLLA. Three PDLA homopolymers with a range of molecular weights were used as the minority (≤5%) component. The presence of the stereocomplex in the PLLA matrix was verified by differential scanning calorimetry (DSC) and optical microscopy. The effectiveness of the in situ formed stereocomplex crystallites for nucleating PLLA crystallization was evaluated using self-nucleation and non-isothermal DSC methods. With only 3 wt% of the 14 kg mol⁻¹ PDLA, nucleation efficiencies near 100% could be obtained. In addition, fast crystallization kinetics were observed in isothermal crystallization experiments at 140 °C. The stereocomplex crystallites were much more effective at enhancing the crystallization rate of PLLA compared to talc, a common nucleating agent.     

成核剂对PET结晶行为及形态结构的影响

系统地研究了四种成核剂:N-A、液晶VectraA950、滑石粉(Talc)、乙撑双硬脂酰胺(EBS)对聚对苯二甲酸乙二醇酯(PET)的结晶行为的影响。采用差式扫描量热仪(DSC)研究了PET/成核剂复合体系的非等温结晶行为,通过小角激光散射(Sals)、X衍射(XRD)对PET/成核剂复合体系的晶体尺寸和晶体结构进行了研究。结果表明,引入成核剂后,PET的结晶行为有较大改善,结晶峰向高温方向移动,且变尖锐,结晶尺寸变小,结晶度提高,除EBS外,均使PET结晶诱导时间减少。在这四种成核剂中,离子聚合物成核剂N-A成核效果最好。     

Film extrusion and film weldability of poly(lactic acid) plasticized with triacetine and tributyl citrate

Film extrusion and welding of biodegradable polymer films are important processes that must be considered in the development of compostable packaging materials. Film extrusion of poly(lactic acid) (PLA) has proved to be rather difficult because of its brittleness, but the flexibility of PLA can be improved by incorporation of a plasticizer in the material. PLA was plasticized with triacetine (TAc) and tributyl citrate (TbC). The blended materials and neat PLA were film extruded and the films were welded with constant heat (CH) welding. The films were analyzed by means of gas chromatography (GC), dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), gel permeation chromatography (GPC), contact angle measurements, and tensile testing. Storage of the plasticized films resulted in an increased crystallinity and changes in the film properties, rendering CH welding difficult. The welding process had no influence on thermal properties, such as cold crystallization temperature, melting temperature, crystallization temperature, and degree of crystallinity, of neat PLA but caused significant changes in the crystallinity of the plasticized materials. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 3239–3247, 2003     

Effect of nucleation and plasticization on the crystallization of poly(lactic acid)

In this paper, different strategies to promote PLA crystallization were investigated with the objective of increasing the crystalline content under typical polymer processing conditions. The effect of heterogeneous nucleation was assessed by adding talc, sodium stearate and calcium lactate as potential nucleating agents. The PLA chain mobility was increased by adding up to 10 wt% acetyl triethyl citrate and polyethylene glycol as plasticizers. The crystallization kinetics were studied using DSC analysis under both isothermal and non-isothermal conditions. The isothermal data showed that talc is highly effective in nucleating the PLA in the 80-120 °C temperature range. In the non-isothermal DSC experiments, the crystallinity developed upon cooling was systematically studied at cooling rates of 10, 20, 40, and 80 °C/min. The non-isothermal data showed that the combination of nucleant and plasticizer is necessary to develop significant crystallinity at high cooling rates. The nucleated and/or plasticized PLA samples were injection molded and the effect of mold temperature on crystallinity was determined. It was possible to mold the PLA formulations using mold temperatures either below 40 °C or greater than 60 °C. At low temperature, the molded parts were nearly amorphous while at high mold temperatures, the PLA formulation with proper nucleation and plasticization was shown to achieve crystallinity levels up to 40%, close to the maximum crystalline content of the material. Tensile mechanical properties and temperature resistance of these amorphous and semi-crystalline materials were examined.     

Synergistic effects of N,N′‐bis (benzoyl) sebacic acid dihydrazide and talc on the physical and mechanical behaviors of poly(l‐latic acid)

The important practical problem of poor heat stability of poly(l ‐lactic acid) (PLLA) is addressed by the addition of N, N′‐bis (benzoyl) sebacic acid dihydrazide (BSAD) and talc as a nucleating agent system. The idea of incorporating talc into the PLLA/BSAD composites is that talc can provide supplementary nucleation effect with very small amount of BSAD (0.2 wt %) and therefore can improve the heat deflection resistance of PLLA materials. Effects of BSAD/talc on morphology, crystallization behavior, heat resistance, and mechanical properties of PLLA/BSAD/talc were investigated after annealing processes. The results indicated that the BSAD/talc system increased the crystallinity from 6.0% of pure PLLA to a maximum 42.9% by the synergistic effects of BSAD and talc increasing the growth of spherulites and nucleation density, respectively. After annealing at different temperatures, the heat deflection temperature (HDT) of PLLA was improved dramatically due to synergistic effects of BSAD/talc between restricted chain movement and acceleration of crystallization. At high temperature (above T_g), the thermo‐mechanical properties of PLLA is mainly determined by the crystallinity and the reinforcement effect of talc acted as a filler. Moreover, effects of BSAD/talc on mechanical properties were discussed. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41454.     

Talc as a nucleating agent and reinforcing filler in poly(lactic acid) composites

The effect of talc on the crystallinity and mechanical properties of a series of poly(lactic acid) (PLA)/talc composites has been investigated. The composites were prepared by melt blending followed by compression molding. It was found that talc acted as a nucleating agent and increased the crystallinity of the PLA from 2% to 25%. There was significant improvement in Young's modulus of the composites with increasing talc addition and these results were found to fit the Halpin Tsai model. Thermo‐mechanical tests confirmed that the combination of increased crystallinity and storage modulus leads to improvement in the heat distortion properties. POLYM. ENG. SCI., 54:64–70, 2014. © 2013 Society of Plastics Engineers     

Poly(lactic acid)/titanium dioxide nanocomposite films: Influence of processing procedure on dispersion of titanium dioxide and photocatalytic activity

Poly(lactic acid)/titanium dioxide (TiO₂) composite films were prepared by direct melt processing using three different procedures (i.e., compression molding, twin‐screw melt extrusion, and melt extrusion and thermoforming). The effect of TiO₂ loading and processing procedures on the phase morphology and on the thermal, mechanical, and barrier properties of the obtained nanocomposites were analyzed respectively by field‐emission scanning electron microscopy‐energy dispersive spectrometry, differential scanning calorimetry, universal testing machine, and water vapor and oxygen permeability measurements. The incorporation of TiO₂ nanoparticles into the poly(lactic acid) matrix increased the crystallinity and improved the barrier properties of the composites. The maximum tensile strength was achieved at the 2% content of TiO₂ for the films produced by compression molding and twin‐screw melt extrusion, whereas the tensile strength for films produced by melt extrusion and thermoforming decreases markedly with an increasing TiO₂ content. The photocatalytic activities of the obtained nanocomposites were investigated by analyzing the degradation of methyl orange. Results confirmed that the processing procedures and the distribution of TiO₂ in the polymer matrix are the key parameters, which rule the photocatalytic behavior of composite films. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers