From Cellulose Nanospheres, Nanorods to Nanofibers: Various Aspect Ratio Induced Nucleation/Reinforcing Effects on Polylactic Acid for Robust-Barrier Food Packaging

The traditional approach toward improving the crystallization rate as well as the mechanical and barrier properties of poly(lactic acid) (PLA) is the incorporation of nanocelluloses (NCs). Unfortunately, little study has been focused on the influence of the differences in NC morphology and dimensions on the PLA property enhancement. Here, by HCOOH/HCl hydrolysis of lyocell fibers, microcrystalline cellulose (MCC), and ginger fibers, we unveil the preparation of cellulose nanospheres (CNS), rod-like cellulose nanocrystals (CNC), and cellulose nanofibers (CNF) with different aspect ratios, respectively. All the NC surfaces were chemically modified by Fischer esterification with hydrophobic formate groups to improve the NC dispersion in the PLA matrix. This study systematically compared CNS, CNC, and CNF as reinforcing agents to induce different kinds of heterogeneous nucleation and reinforce the effects on the properties of PLA. The incorporation of three NCs can greatly improve the PLA crystallization ability, thermal stability, and mechanical strength of nanocomposites. At the same NC loading level, the PLA/CNS showed the highest crystallinity (19.8 ± 0.4%) with a smaller spherulite size (33 ± 1.5 μm), indicating that CNS, with its high specific surface area, can induce a stronger heterogeneous nucleation effect on the PLA crystallization than CNC or CNF. Instead, compared to PLA, the PLA/CNF nanocomposites gave the largest Young's modulus increase of 350 %, due to the larger aspect ratio/rigidity of CNF and their interlocking or percolation network caused by filler-matrix interfacial bonds. Furthermore, taking these factors of hydrogen bonding interaction, increased crystallinity, and interfacial tortuosity into account, the PLA/CNC nanocomposite films showed the best barrier property against water vapor and lowest migration levels in two liquid food simulates (well below 60 mg kg^-1 for required overall migration in packaging) than CNS- and CNF-based films. This comparative study was very beneficial for selecting reasonable nanocelluloses as nucleation/reinforcing agents in robust-barrier packaging biomaterials with outstanding mechanical and thermal performance.