Crystallization kinetics, structure and applications of PLA stereocomplexes

Poly(lactic acid), or PLA, is a family of linear thermoplastic polyesters that has experienced strong market growth over the past decade. The enthusiasm for PLA originates from its bio-based nature, its good properties and its biodegradability. However, some of PLA deficiencies such as low thermal resistance and low melt elasticity have limited the development of this polymer. It is noteworthy that the lactic acid monomer has two stereo-isomers (L and D) that can be polymerized respectively into PLLA and PDLA but surprisingly, blending of PLLA and PDLA can lead to the formation of a “stereocomplex” which has a distinct crystalline structure from that of the homopolymers. This crystalline form has a melting point 50 oC greater than the crystalline PDLA or PLLA forms, thus it has by itself an interest in terms of heat resistance. In this work, the use of small amounts of PDLA (0-5%) in a matrix of PLLA will be explored. Particular emphasis will be on the nucleating ability of the stereocomplex (formed at high temperature) on PLLA crystallization and on its effect on the blends rheological properties. The current thesis comprises a literature review on PLA crystallization followed by four experimental sections. The objective of the literature review was to reinterpret the large body of data available on PLA in order to draw clear conclusions on PLA crystallization. The first experimental part of the work focused on the kinetics and conditions of stereocomplex formation in the melt state. It was found that stereocomplex formation is slow in the melt processing temperature range of PLLA (180 oC). Co-existence of a so-called “network structure” with a spherulitic structure was revealed for the first time. It was shown that the network structure has a lower melting point than the spherulitic one. In the second part of the work, stereocomplexation kinetics was improved significantly to match it with the fast cooling cycles typical of melt processing techniques. This was achieved by adding nucleating agents that initiated crystallization at higher temperatures and plasticizers that enabled more polymer fluidity. This strategy enabled an order of magnitude decrease in crystallization time. The third part of the work was the investigation of rheological properties upon formation of the stereocomplex structure in 0-5% PDLA in PLLA blends. Due to its higher melting point, the stereocomplex can be preserved in molten PLLA and alter significantly the blend melt rheology. Stereocomplex formation was monitored through rheological measurements and compared to classical calorimetry data. The presence of the stereocomplex lead to a significant increase in viscosity and in melt elasticity explained through the presence of physical crosslink points in the amorphous matrix. Finally, in the last experimental part of the work, the stereocomplex was employed to enhance PLA foaming behavior. Foaming visualization experiments as well as batch foaming tests showed that the presence of the stereocomplex can increase bubble nucleation density and led to a finer and more uniform foam morphology due to its nucleating effect and to the increased melt elasticity. The literature review and the three first experimental sections are presented in Peer-reviewed journal format. The last experimental section is meant as an exploratory and prospective part for the project and will not be submitted for publication.