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The effects of incorporating hyperbranched polymers (HBPs) and different nanoclays [Cloisite® 30B and halloysite nanotubes (HNT)] on the mechanical, morphological, and thermal properties of solid and microcellular poly(hydroxybutyrate-co-hydroxyvalerate) (PHBV) were investigated. According to the X-ray diffraction (XRD) and transmission electron microscopy (TEM) analyses, Cloisite 30B exhibited a combination of exfoliation and heterogeneous intercalation structure for both solid and microcellular PHBV–12% HBP–2% Cloisite 30B nanocomposites. TEM images indicated that HNTs were uniformly dispersed throughout the PHBV matrix. The addition of 2% nanoclays improved the thermal stability of the resulting nanocomposites. The addition of HBP+poly(maleic anhydride-alt-1-octadecene) (PA), Cloisite 30B, and HNT reduced the average cell size and increased the cell density of the microcellular components. The addition of (HBP+PA), Cloisite 30B, and HNT also increased the degree of crystallinity for both solid and microcellular components in comparison with neat PHBV. Also, with the addition of 12% (HBP+PA), the area under the tan-δ curve, specific toughness, and strain-at-break of the PHBV–HBP nanocomposite increased significantly for both solid and microcellular specimens, whereas the storage modulus, specific Young's modulus, and specific tensile strength decreased. The addition of 2% nanoclays into the PHBV–HBP nanocomposites improved the storage modulus, specific Young's modulus, and specific tensile strength of the PHBV–HBP–nanoclay-based nanocomposites, but they were still lower than those of the neat PHBV. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers

Poly(ethylene terephthalate) (PET) resin is one of the most widely used thermoplastics, especially in packaging. Because thermal and hydrolytic degradations, recycled PET (RPET) exhibits poor mechanical properties and lacks moldability. The effects of adding elastomeric modifiers, chain extenders (CE), and poly(butylene adipate-co-terephthalate), PBAT, as a toughener to RPET on its moldability and mechanical property were investigated. Melt blending of RPET with CE, thermoplastic elastomer (TPE), and/or PBAT was performed in a thermokinetic mixer (K-mixer). The blended materials were then injection molded to produce tensile specimens. Various techniques were used to study the mechanical properties, rheological properties, compatibility, and crystallization behavior of the RPET blends. By melt blending with proper additives, recycled PET regained its moldability, thereby enabling the recycling of RPET. Furthermore, the addition of CE greatly enhanced the mechanical properties of RPET. While the RPET and TPE blends also showed improved mechanical properties, the improvement was less significant and the blends were often immiscible due to the difference in polarities between RPET and TPE. Finally, it was found that the mechanical properties of RPET blends depended on the prior thermal history of the material and could be improved with an extra annealing step that increased the degree of crystallinity. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers

Solid and microcellular specimens made of poly (3-hydroxybutyrate-co-3-hydroxyvalerate)(PHBV)/ poly(butylene adipate-co-terephthalate) (PBAT) blends with three different weight ratios (i.e., PHBV/PBAT = 98.5/1.5 (Y1000P), 45/55 (5010P), and 30/70 (6010P), respectively) were prepared via conventional and microcellular injection molding process, respectively. Various properties such as miscibility, cell morphology, thermal, and mechanical properties were investigated. Compared with the microcellular specimens, the solid specimens showed better miscibility. Increasing the PBAT content led to higher specific toughness and strain-at-break, but lower specific modulus and specific strength for both solid and microcellular specimens. In addition, increasing the PBAT content increased the average cell size, but decreased the cell density of the microcellular samples. Finally, the crystallinity of PHBV in the PHBV/PBAT blends decreased significantly with increasing PBAT content for both solid and microcellular specimens. POLYM. ENG. SCI., 50:1440-1448, 2010. © 2010 Society of Plastics Engineers.

The effects of adding epoxy-functionalized chain-extender (CE) and processing conditions such as die temperature on the cell morphology, volume expansion ratio (VER), open cell content (OCC), and crystallization of microcellular extruded polylactide (PLA) were investigated. When compared with pure PLA, the addition of talc decreased the average cell size and increased the cell density. Moreover, the simultaneous addition of talc and CE led to denser and more uniform cell structure up until 1.0% CE content. In general, the volume expansion ratio and open cell content of all the formulations decreased with the die temperature. The addition of talc decreased both VER and OCC, whereas the addition of CE increased both. The die temperature did not affect the degree of crystallinity significantly. The addition of talc increased the crystallinity, but the addition of CE decreased it. Finally, the molecular weight of PLA increased significantly with the addition of CE. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers

Biobased and biodegradable polylactide (PLA)-pine wood flour (PWF) composites were investigated as a means to reduce the overall material cost and tailor the material properties. The composites were prepared using a kinetic-mixer and an injection molding machine. The tensile modulus of the PLA-PWF composites increased with the PWF content whereas the toughness and strain-at-break decreased. The tensile strength remained the same irrespective of the PWF content (up to 40%). The storage modulus also increased with the PWF content. Additionally, composites containing PWF treated with silane showed higher storage modulus than those without the silane treatment. The area integration underneath the tan δ peaks decreased with increasing PWF, indicating that the PLA-PWF composites exhibited more elastic behavior with increasing PWF. The degree of crystallinity of the PLA-PWF composites increased significantly with the PWF content. Furthermore, the treatment of PWF with silane had a positive effect on its nucleating ability, as treated PLA-PWF composites showed higher crystallinity compared with their untreated counterparts. The morphology of the fracture surfaces were studied using a scanning electron microscope. Finally, a Halpin-Tsai analytical model to predict Young's modulus of PLA-PWF composites was presented to compare the theoretical results with that of experimental results. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers

Three types of composites, namely, polylactide (PLA)/nanoclay, PLA/core–shell rubber, and PLA/nanoclay/core–shell rubber, were melt compounded via a corotating twin-screw extruder. The effects of two types of organically modified montmorillonite nanoclays (i.e., Cloisite®30B and 20A), two types of core (polybutylacrylate)–shell (polymethylmethacrylate) rubbers (i.e., Paraloid EXL2330 and EXL2314), and the combination of nanoclay and rubber on the mechanical and thermal properties of the composites were investigated. According to X-ray diffraction and transmission electron microscopy analyses, both types of PLA/5 wt% nanoclay composites had an intercalated morphology. In comparison with pure PLA, both types of PLA/5 wt% nanoclay composites had an increased modulus, similar impact strength, slightly reduced tensile strength, and significantly reduced strain at break. On the other hand, PLA/EXL2330 composites with a rubber loading level of 10 wt% or higher had a much higher impact strength and strain at break, but a lower modulus and strength when compared with pure PLA. The simultaneous addition of 5 wt% nanoclay (Cloisite®30B) and 20 wt% EXL2330 resulted in a PLA composite with a 134% increase in impact strength, a 6% increase in strain at break, a similar modulus, and a 28% reduction in tensile strength in comparison with pure PLA. POLYM. ENG. SCI. 46:1419–1427, 2006. © 2006 Society of Plastics Engineers

The effects of submicron core-shell rubber (CSR) particles, nanoclay fillers, and molding parameters on the mechanical properties and cell structure of injection-molded microcellular polyamide-6 (PA6) composites were studied. The experimental results of PA6 nanocomposites with 5.0 and 7.5 wt% nanoclay loadings and of CSR-modified PA6 composites with 0.5 and 3.1 wt% CSR loadings were compared to their neat resin counterparts. This study found that nanoclay was more efficient in promoting a smaller cell size, larger cell density, and higher tensile strength for microcellular injection molding parts. A higher nanoclay loading led to more brittle behavior for microcellular parts. It was found that a proper amount of CSR particles could be added to the microcellular injection-molded PA6 to reduce the cell size, increase the cell density, and enhance the toughness of the molded part. However, CSR particles were less effective cell nucleation agents as compared to nanoclay for producing desirable cell structures, and a higher CSR loading was found to have diminishing effects on the process and on the properties of the parts. POLYM. ENG. SCI., 45:773–788, 2005. © 2005 Society of Plastics Engineers

The effects of adding nanoclay to polyamide-6 (PA-6) neat resin, and the effects of processing parameters on cell density and size in microcellular injection-molded components were investigated. In addition, the crystal sizes, structures, and orientation were analyzed with the use of x-ray diffraction (XRD) and a polarized optical microscope. The standard ASTM D 638-02 tensile bars for the analyses were molded according to a fractional four-factor, three-level, L9 Taguchi design of experiment (DOE) with varying melt temperature, injection speed, supercritical fluid (SCF) concentration, and shot size. It was found that the presence of montmorillonite (MMT) nanoclay greatly reduced the size of the cells and crystals, but increased their density in comparison with neat resin processed under identical molding conditions. In addition, at the sprue section downstream of the machine nozzle, cell size gradually decreased from the part center toward the skin for both the neat resin and the nanocomposite. It was also found that shot size was the most important processing parameter for both the neat resin and nanocomposite in affecting cell density and size in microcellular injection molding components. Weakly preferred crystal orientations were observed on the surface of microcellular injection-molded PA-6/MMT tensile bars. Finally, the addition of nanoclay in PA-6 neat resin facilitated the formation of γ-phase crystals in the molded components. Polym. Eng. Sci. 45:52–61, 2005. © 2004 Society of Plastics Engineers.