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Cellulose nanocrystal (CNC)-reinforced composites are gaining commercial attention on account of their high strength and sustainable sourcing. Grafting polymers to the CNCs in these composites has the potential to improve their properties, but current solution-based synthesis methods limit their production at scale. Utilizing dynamic hindered urea chemistry, a new method for the melt-functionalization of cellulose nanocrystals has been developed. This method does not require toxic solvents during the grafting step and can achieve grafting densities competitive with state-of-the-art solution-based grafting methods. Using cotton-sourced, TEMPO-oxidized CNCs, multiple molecular weights of poly(ethylene glycol) (PEG) as well as dodecane, polycaprolactone, and poly(butyl acrylate) were grafted to the CNC surface. With PEG-grafted nanoparticles, grafting densities of 0.47 chains nm−2 and 0.10 chains nm−2 were achieved with 2000 and 10,000 g mol−1 polymer chains respectively, both of which represent significant improvements over previous reports for solution-based PEG grafting onto CNCs. 

Abstract Poly(lactic acid) (PLA) is a commercially available bio‐based polymer that is a potential alternative to many commodity petrochemical‐based polymers. However, PLA's thermomechanical properties limit its use in many applications. Incorporating polymer‐grafted cellulose nanocrystals (CNCs) is one potential route to improving these mechanical properties. One key challenge in using these polymer‐grafted nanoparticles is to understand which variables associated with polymer grafting are most important for improving composite properties. In this work, poly(ethylene glycol)‐grafted CNCs are used to study the effects of polymer grafting density and molecular weight on the properties of PLA composites. All CNC nanofillers are found to reinforce PLA above the glass transition temperature, but non‐grafted CNCs and CNCs grafted with short PEG chains (<2 kg mol⁻¹) are found to cause significant embrittlement, generally resulting in less than 3% elongation‐at‐break. By grafting higher molecular weight PEG (10 kg mol⁻¹) onto the CNCs at a grafting density where the polymer chains are predicted to be in the semi‐dilute polymer brush conformation (~0.1 chains nm⁻²), embrittlement can be avoided.