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<p>The development of cushioning material with excellent resilience, high compressive strength, and sustainability is essential for engineering development, and environmental protection. In this study, we report a simple and effective method to produce poly (butylene adipate-<i>co</i>-terephthalate) (PBAT)/poly(lactic acid) (PLA) foams with excellent resilience and thermal stability by introducing a small amount of poly (D-lactic acid) (PDLA) through melt blending and supercritical CO<sub>2</sub> foaming. PDLA interacts with poly (L-lactic acid) PLLA chains to form stereocomplex (SC) crystals, which act as rheological modifiers and through tuning the PLLA/PDLA ratio, promote the formation of a rigid co-continuous PLA network within PBAT matrices. The incorporation of SC microcrystals significantly improved the mechanical strength and thermal stability of the foams compared to conventional PBAT/PLA blends that exhibit island-like morphology. The main findings include the production of foams with high cell density (~ 1 ± 0.5 × 10<sup>9</sup> cells/cm<sup>3</sup>), uniform bubble size (~ 15&#xa0;μm), maximum stress at 50% strain of 0.3&#xa0;MPa, permanent deformation rate of less than 10%, and minimum buffer coefficients of ~ 3.0. In addition, SC crystals considerably retarded the dimensional changes at elevated temperatures, thus improving the stability of the foams. This study highlights a practical strategy for designing high-performance, biodegradable polymer foams, with potential applications in sustainable packaging and protective materials.</p>

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PLA Stereocomplexes-Induced Co-continuous Like Structures in PBAT Foams: A Strategy to Resist Shrinkage, Maintain Resilience and Improve Compressive Properties

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Qifan Yang,
  • Yi Ding,
  • Jiahui Liu,
  • Xueyao Lv,
  • Xiangdong Wang

摘要

The development of cushioning material with excellent resilience, high compressive strength, and sustainability is essential for engineering development, and environmental protection. In this study, we report a simple and effective method to produce poly (butylene adipate-co-terephthalate) (PBAT)/poly(lactic acid) (PLA) foams with excellent resilience and thermal stability by introducing a small amount of poly (D-lactic acid) (PDLA) through melt blending and supercritical CO2 foaming. PDLA interacts with poly (L-lactic acid) PLLA chains to form stereocomplex (SC) crystals, which act as rheological modifiers and through tuning the PLLA/PDLA ratio, promote the formation of a rigid co-continuous PLA network within PBAT matrices. The incorporation of SC microcrystals significantly improved the mechanical strength and thermal stability of the foams compared to conventional PBAT/PLA blends that exhibit island-like morphology. The main findings include the production of foams with high cell density (~ 1 ± 0.5 × 109 cells/cm3), uniform bubble size (~ 15 μm), maximum stress at 50% strain of 0.3 MPa, permanent deformation rate of less than 10%, and minimum buffer coefficients of ~ 3.0. In addition, SC crystals considerably retarded the dimensional changes at elevated temperatures, thus improving the stability of the foams. This study highlights a practical strategy for designing high-performance, biodegradable polymer foams, with potential applications in sustainable packaging and protective materials.