Effect of bubble nucleating agents derived from biochar on the foaming mechanism of poly lactic acid foams

Improvement and new technologies for effective poly (lactic acid) (PLA) foaming are still in developing. This study examines the ability of biochar (BC) to assist in PLA foaming through a supercritical CO2 batch process. To determine suitable foaming parameters, process optimization was conducted on neat PLA films. BC particles derived from three different sources - sludge (SLG), pistachio shells (PST) and green waste (GW) were ground, and ball milled to a microscale and then blended with PLA. The PLA/BC blends were extruded into films and then batch foamed. The effect of BC was found to be concentration and source dependent. At 0.25 wt%, BC particles were found to be effective nucleating agents showing an increase up to four orders of magnitude in cell density and 10-fold reduction in the mean pore size compared to the neat PLA foams. An increase in BC content to 0.5 and 1 wt% induced particle aggregation, which resulted in non-homogenous foam densities. BC particles derived from SLG were the most effective nucleating agents due to their narrow size distribution, improved dispersibility and mesoporous surface. This work shows that BC can act as an effective bio-derived nucleating agent for PLA.