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Novel super toughened bioplastics are developed through controlled reactive extrusion processing, using a very low content of modifier, truly a new discovery in the biodegradable plastics area. The super toughened polylactide (PLA) blend showing a notched impact strength of ∼1000 J/m with hinge break behavior is achieved at a designed blending ratio of PLA, poly(butylene succinate) (PBS), and poly(butylene adipate- co -terephthalate) (PBAT), using less than 0.5 phr peroxide modifier. The impact strength of the resulting blend is approximately 10 times that of the blend with the same composition without a modifier and ∼3000% more than that of pure PLA. Interfacial compatibilization among the three biodegradable plastics took place during the melt extrusion process in the presence of a controlled amount of initiator, which is confirmed by scanning electron microscopy and rheology analysis. The synergistic effect of strong interfacial adhesion among the three blending components, the decreased particle size of the most toughened component, PBAT, to ∼200 nm, and its uniform distribution in the blend morphology result in the super tough biobased material. One of the key fundamental findings through the in situ rheology study depicts that the radical reaction initiated by peroxide occurs mainly between PBS and PBAT and not with PLA. Thus, the cross-linking degree can be controlled by adjusting renewable sourced PLA contents in the ternary blend during reactive extrusion processing. The newly engineered super toughened PLA with high stiffness and high melt elasticity modulus could reasonably serve as a promising alternative to traditional petroleum plastics, where high biobased content and biodegradability are required in diverse sustainable packaging uses.

Super Toughened Poly(lactic acid)-Based Ternary Blends via Enhancing Interfacial Compatibility