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Ineffective sorting of post-consumer plastics remains one of the major obstacles in the recycling of plastics. Consequently, these highly heterogeneous, mixed post-consumer plastics will end up in landfill or have to be incinerated as repurposing them directly would lead to a polymer blend with inferior quality for many end-uses. In this work, we demonstrate the use of carbon fibers (CFs) to practically upgrade the mechanical properties of mixed plastics, adding value to them. This will create a stronger demand for mixed plastics to be used in various engineering applications. Using polyethylene terephthalate (PET) and polypropylene (PP) as the model immiscible polymer blend, we showed that the incorporation of CFs increased the tensile, flexural, and single-edge notched fracture toughness of the resulting CF-reinforced PET/PP composite blends. Despite the high environmental burden associated with the production of CFs, cradle-to-grave life-cycle analysis showed that CF-reinforced PET/PP composites have a lower environmental impact than the life-cycle scenarios of “doing nothing” and repurposing immiscible PET/PP blends as it is without CF reinforcement. This can be attributed to the weight saving achieved, a direct result of their higher mechanical performance. Our work opens up opportunities for the use of mixed plastics in various higher value applications such that they can be diverted away from landfill or incineration, in line with the concept of circular economy.

Structure-mechanical properties relationships of nanocellulose reinforced polymer composites are studied in computational experiments. A code for the automatic generation of 3D unit cell finite element models of nanocellulose reinforced polymers with "snake"-shaped nanocellulose fibrils is developed. The code allows the generation of pre-defined nanocomposites structures, with varied angles between nanocellulose snakes segments and hydrogen bonds between nanocellulose fibrils.In a series of computational studies, it is demonstrated that the nanocellulose reinforcement leads to higher stiffness of the matrix polymer, but makes it more brittle.

TEMPO-oxidised cellulose fibres are often explored as nano-reinforcement for polymers. However, it is unclear whether micrometre-sized TEMPO-oxidised cellulose fibres also possess similar reinforcing potential. In this work, we report the mechanical response of polypropylene (PP) composites reinforced with TEMPO-oxidised cellulose (TOC) of different fibre widths. Micrometre-sized TOC fibres (TOCF) containing sodium carboxylate (TOCF-Na) and free hydroxyl (TOCF-H) groups, as well as nano-sized TOC nanofibrils (TOCN) were produced from dissolving pulp and incorporated into PP matrix via melt-extrusion. It was found that model PP composites containing micrometre-sized TOCF-Na and TOCF-H possessed the highest tensile modulus of up to 2.5 GPa; 40% improvement over neat PP and 30% increase over PP/TOCN composite. No significant differences in the tensile strength of PP/TOCF-Na and PP/TOCF-H composites were observed when compared to neat PP. The incorporation of nano-sized TOCN into PP however, led to a 6% decrease in tensile strength. Single-edge notched beam fracture toughness test further showed that PP/TOCN composite possessed the lowest fracture toughness of 2.52 MPa m1/2; a decrease of 18% over PP reinforced with micrometre-sized TOCF-Na and TOCF-H. Our study shows that micrometre-sized TOCFs serve as better reinforcement for polymers compared to nano-sized TOCN. This is attributed to the better dispersion of TOCF in the PP matrix. Furthermore, the presence of surface microfibrillation on TOCFs also enhanced the quality of the TOCF-PP interface through mechanical interlocking and local stiffening of the PP matrix.

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