Ultrasound-Assisted Melt Extrusion of Polymer Nanocomposites

A review of the latest developments in ultrasound-assisted melt extrusion of polymer nanocomposites is presented. In general, the application of ultrasound waves during melt extrusion of polymer in the presence of nanoparticles results in a more homogeneous dispersion of the nanoparticles in the polymer matrix. In spite of this, a lack of understanding in the field has hindered the development of this processing technique. Based on the analysis of literature on the field, key aspects are identified for a better understanding of the physical and chemical effects of ultrasound waves and the fabrication of polymer nanocomposites by means of melt extrusion

Preparation and Characterization of Electrically Conductive Polymer Nanocomposites with Different Carbon Nanoparticles

Carbon nanoparticles possess a combination of high electrical and thermal transport properties, as well as low density and different morphologies that make them a good choice to reinforce plastics. Polymer nanocomposites offer great expectations for new and unexpected applications due to the possibility of changing their electrical/thermal behavior by adding nanoparticles while retaining the flexibility and processability of plastics. The possibility of electrical and thermal conduction in a polymer matrix with low amounts of nanoparticles brings opportunity for high demanding applications such as electrical conductors, heat exchangers, sensors, and actuators. Polyolefin nanocomposites offer a significant challenge due to their insulative nature and low affinity for carbon nanoparticles; due to the latter, new production tendencies are proposed and investigated

Effect of Sorbitol Templates on the Preferential Crystallographic Growth of Isotactic Polypropylene Wax

The crystallization of isotactic polypropylene wax (iPP) in the presence of different sorbitol structures was studied. Dibenzylidene Sorbitol (DBS), as well as two of its derivatives with one or two methyl groups in the DBS molecule (MDBS and DMDBS, respectively), were tested as nanometer-size fibrillar templates. The early nucleation stage and crystal morphology were analyzed in Real-Time Wide-Angle X-ray Scattering (WAXS) and polarized optical microscopy (POM). It was found that the iPP crystals showed an α-phase unit cell for the three different sorbitols. However, a preferential crystal growth in the plane (040) was observed for iPP–MDBS. The macrostructure morphology of the iPP–DBS and iPP–DMDBS wax compounds was spherulitic, while nodular macrocrystals were observed for the iPP–MDBS compound. It was concluded that the MDBS template promoted a lower interface energy because of its match with the c-axis of the iPP wax crystals, whereas, in the case of the DBS and DMDBS templates, the preferential plane was the (110), characteristic of the iPP spherulitic arrangement

Insights on the Molecular Behavior of Polypropylene in the Process of Ultrasonic Injection Molding

Product miniaturization is a constant trend in industries that demand ever-smaller products that can be mass produced while maintaining high precision dimensions in the final pieces. Ultrasonic micro injection molding (UMIM) technology has emerged as a polymer processing technique capable of achieving the mass production of polymeric parts with micro-features, while still assuring replicability, repeatability, and high precision, contrary to the capabilities of conventional processing technologies of polymers. In this study, it is shown that the variation of parameters during the UMIM process, such as the amplitude of the ultrasound waves and the processing time, lead to significant modification on the molecular structure of the polymer. The variation of both the amplitude and processing time contribute to chain scission; however, the processing time is a more relevant factor for this effect as it is capable of achieving a greater chain scission in different areas of the same specimen. Further, the presence of polymorphism within the samples produced by UMIM is demonstrated. Similarly to conventional processes, the UMIM technique leads to some degree of chain orientation, despite the fact that it is carried out in a relatively small time and space. The results presented here aim to contribute to the optimization of the use of the UMIM process for the manufacture of polymeric micro parts

Ultrasound-Assist Extrusion Methods for the Fabrication of Polymer Nanocomposites Based on Polypropylene/Multi-Wall Carbon Nanotubes

Isotactic polypropylenes (iPP) with different melt flow indexes (MFI) were used to fabricate nanocomposites (NCs) with 10 wt % loadings of multi-wall carbon nanotubes (MWCNTs) using ultrasound-assisted extrusion methods to determine their effect on the morphology, melt flow, and electrical properties of the NCs. Three different types of iPPs were used with MFIs of 2.5, 34 and 1200 g/10 min. Four different NC fabrication methods based on melt extrusion were used. In the first method melt extrusion fabrication without ultrasound assistance was used. In the second and third methods, an ultrasound probe attached to a hot chamber located at the exit of the die was used to subject the sample to fixed frequency and variable frequency, respectively. The fourth method is similar to the first method, with the difference being that the carbon nanotubes were treated in a fluidized air-bed with an ultrasound probe before being used in the fabrication of the NCs with no ultrasound assistance during extrusion. The samples were characterized by MFI, Optical microscopy (OM), Scanning electron microscopy (SEM), Transmission electron microscopy (TEM), electrical surface resistivity, and electric charge. MFI decreases in all cases with addition of MWCNTs with the largest decrease observed for samples with the highest MFI. The surface resistivity, which ranged from 1013 to 105 Ω/sq, and electric charge, were observed to depend on the ultrasound-assisted fabrication method as well as on the melt flow index of the iPP. A relationship between agglomerate size and area ratio with electric charge was found. Several trends in the overall data were identified and are discussed in terms of MFI and the different fabrication methods

Synthesis of Nylon 6/Modified Carbon Black Nanocomposites for Application in Uric Acid Adsorption

High uric acid levels cause different clinic conditions. One of them is hyperuricemia, which leads to kidney damage. A solution for eliminating uric acid in the blood is by hemodialysis, which is performed using nanocomposite membranes. In this work, Nylon 6 nanocomposites were synthesized with modified carbon black (MCB), which were considered candidate materials for hemodialysis membranes. The modification of carbon black was made with citric acid using the variable-frequency ultrasound method. The new MCB was characterized by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), X-ray diffraction (XRD), transmission electron microscopy (TEM), and dispersion tests. Nylon 6/MCB nanocomposites were processed using the ultrasound-assisted melt-extrusion method to improve the dispersion procedure of the nanoparticles. The Nylon 6/MCB nanocomposites were characterized by FTIR, TGA, and differential scanning calorimetry (DSC). These were assessed for the absorption of toxins and hemocompatibility. MBC and nanocomposites showed excellent uric acid removal (78–82%) and hemocompatibility (1.6–1.8%). These results suggest that Nylon 6/MCB nanocomposites with low loading percentages can be used on a large scale without compatibility problems with blood

Antimicrobial Property of Polypropylene Composites and Functionalized Copper Nanoparticles

Copper nanoparticles (CuNPs) functionalized with polyethyleneimine (PEI) and 4-aminobutyric acid (GABA) were used to obtain composites with isotactic polypropylene (iPP). The iPP/CuNPs composites were prepared at copper concentrations of 0.25–5.0 wt % by melt mixing, no evidence of oxidation of the CuNP was observed. Furthermore, the release of copper ions from iPP/CuNPs composites in an aqueous medium was studied. The release of cupric ions was higher in the composites with 2.5 and 5.0 wt %. These composites showed excellent antibacterial activity (AA) toward Pseudomona aeruginosa (P. aeruginosa) and Staphylococcus aureus (S. aureus). The incorporation of CuNP into the iPP polymeric matrix slightly decreased the thermal stability of the composite material but improved the crystallinity and the storage modulus. This evidence suggests that CuNPs could work as nucleating agents in the iPP crystallization process. The iPP/CuNPs composites presented better AA properties compared to similar composites reported previously. This behavior indicates that the new materials have great potential to be used in various applications that can be explored in the future

Antimicrobial Properties of Polyester/Copper Nanocomposites by Melt-Spinning and Melt-Blowing Techniques

In this study, textile fiber prototypes based on polyester and different Cu nanoparticles (CuNP) content were produced using melt-spinning to obtain bi-component multifilament fibers and melt-blowing to obtain non-woven fabrics. The prototypes were tested against pathogenic microorganisms such as S. aureus, E. coli, and C. albicans. It was shown that bi-component fibers offer excellent protection against pathogens, with up to 99% growth inhibition with 0.5% w/w for S. aureus and E. coli; meanwhile, non-woven fabric only shows activity against E. coli from 0.1% w/w of CuNP. Using different analytical techniques, it was possible to identify that the CuNP were confined exclusively in the outer cover of the bi-component fibers which may be associated with increased antimicrobial activity compared to the fibers in the non-woven fabric. The use of polymeric nanocomposites based on polyester/copper offers an alternative of great interest due to the versatility of the raw material and the high efficiency of copper nanoparticles as an antimicrobial additive