Extrusion foaming of Poly(lactic acid)/Rice straw composites: Opposing effects of eco-friendly physical/chemical treatment and compatibilization methods

In this study, the effects of two environmentally-friendly pulping methods along with two different reactive compatibilization methods on the foamability of poly (lactic acid) (PLA)/rice straw (RS) biocomposites have been investigated. RS as an annually renewable agricultural waste is low-cost and available. Melt-compounding and melt-foaming processes were performed through a twin-screw extrusion processing. The correlations between processing and microstructure were studied. The findings show that the RS pulping with sodium bicarbonate (SB) solution leads to the lignocellulosic particles with a porous structure. The structure causes the filler/matrix mechanical engagement and improves the interfacial adhesion and rheological properties, hence forming smaller cells with the narrowest cell size distribution. In contrast, applying ultrasound waves on the RS pulp brings the particles to very smooth surfaces. These surfaces have the highest activity at the cell nucleation stage and considerably increase the foam’s cell density. The reactive compatibilizers based on epoxy and maleic anhydride groups show opposing effects on the biocomposite microstructure, depending on the RS pulp type. The use of the reactive compatibilizers in the PLA/RS pulp treated with SB led to lighter foams with larger cells and higher cell densities and void fractions. Whereas the incorporation of the compatibilizers into the biocomposites containing RS pulp treated with SB and ultrasonic waves resulted in noticeably lower cell density and larger foam density. The extruded biocomposite foams with closed-cell microstructure can be used in insulation and packaging applications.