Shaoting
Lin
a,
Changyong
Cao
a,
Qiming
Wang
a,
Mark
Gonzalez
a,
John E.
Dolbow
b and
Xuanhe
Zhao
*ac
aDepartment of Mechanical Engineering and Materials Science, Duke University, Durham, NC 27708, USA. E-mail: zhaox@mit.edu
bDepartment of Civil and Environmental Engineering, Duke University, Durham, NC 27708, USA
cSoft Active Materials Laboratory, Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, MA 02139, USA
First published on 30th June 2014
Hydrogels' applications are usually limited by their weak mechanical properties. Despite recent great progress in developing tough hydrogels, it is still challenging to achieve high values of stretchability, toughness and modulus all together in synthetic hydrogels. In this paper, we designed highly stretchable, tough, yet stiff hydrogel composites via a combination of nanoscale hybrid crosslinking and macroscale fiber reinforcement. The hydrogel composites were constructed by impregnating a 3D-printed thermoplastic-fiber mesh with a tough hydrogel crosslinked both covalently and ionically. The hydrogel composites can achieve a fracture energy of over 30
000 J m−2, a modulus of over 6 MPa, and can be stretched over 2.8 times even in the presence of large structural defects. The enhancement of toughness in the new hydrogel composites relies on multiple pairs of toughening mechanisms which span over multiple length scales. A theoretical model is further developed to predict the toughness and modulus of the hydrogel composites and guide the design of future materials.
In addition, the general principle for the design of tough hydrogels3 is to implement mechanisms for dissipating mechanical energy and maintaining high elasticity. However, existing tough hydrogels usually rely on a single pair of toughening mechanisms (see Table 1).1–3,13 If either of the mechanisms becomes invalid under mechanical or environmental loads, the hydrogel will lose its high toughness. For example, tough hydrogels that rely on long-chain networks to maintain high elasticity and reversible crosslinking to dissipate mechanical energy will become weak and/or brittle, if the reversible crosslinkers in them are eliminated.12
Here, we report a novel hydrogel that contains around 80% water but can achieve an extremely high toughness (>30 kJ m−2), a high modulus (>6 MPa), and can be stretched over 2.8 times even in the presence of large structural defects. Moreover, the new hydrogel innovatively integrates multiple toughening mechanisms across multiple length scales to make it more robust under mechanical and environmental loads than existing tough hydrogels (Table 1). At the nanoscale, we interpenetrate a physically crosslinked short-chain polymer network with a chemically crosslinked long-chain network to form a tough hydrogel with hybrid crosslinking.12 The reversible crosslinking of physical crosslinkers dissipates mechanical energy in the hydrogel under deformation, while the long-chain network maintains the high elasticity. At the macroscale, we construct a thermoplastic-elastomer fiber mesh with 3D printing and infuse the hydrogel into the mesh. The stiff yet stretchy fibers lead to a high modulus for the composite at moderate deformation. Under large deformations, the plastic deformation and fracture of fibers significantly dissipate mechanical energy while the stretchy hydrogel can still maintain the integrity of the composite (Table 1).
The pure-shear test was used to measure the fracture energy, stiffness, and critical stretch of the fiber-reinforced hydrogel (Fig. S2†).25–27 In brief, two identical pieces of the fiber-reinforced hydrogel were fabricated with the same thickness T, width W and high H, where W ≫ H ≫ T. Both pieces of samples were clamped along their long edges with rigid plates. A notch was introduced into the first sample, which was then gradually pulled to a critical stretch λc until a crack began to propagate. Thereafter, the second sample without notch was uniformly stretched to the same stretch as λc, with nominal stress s recorded as a function of the stretch λ. Based on the measured data, the fracture energy of the gel can be calculated as25,26
![]() | (1) |
![]() | (2) |
Fig. 2a and Video S1† show the deformation and fracture processes of a fiber-reinforced hydrogel (A∥ = 1.93%, A⊥ = 4.07%) with a notch under the pure-shear test. Since both the hydrogel and the fiber mesh are relatively stretchable, the tip of the notch is blunted as the sample is gradually deformed28 (Fig. 2a). Meanwhile, the fiber and the hydrogel matrix begin to detach from each other under subsequent deformation, owing to their weak adhesion (Fig. 2a). As the stretch further increases, fibers in a segment perpendicular to the notch plane begin to fracture. To be conservative, we regard the stretch when the first fiber begins to fracture as the critical stretch of the fiber-reinforced hydrogel, λc, to measure and calculate its fracture energy (Fig. S2† and 2). However, it should be noted that even after all the fibers in the segment are fractured, the remaining hydrogel can still be highly stretched, maintaining the integrity of the composite (Fig. 2a). Therefore, the fracture process of the fiber-reinforced alginate–PAAm hydrogel is distinctly different from those of traditional fiber-reinforced composites, where fibers usually bridge the cracked matrices.29,30 In the current study, conversely, the fibers are first fractured, while the highly stretchable hydrogel matrix maintains the integrity of the sample (Fig. 2a).
Then, in Fig. 3a we plot the stress–stretch curve of the un-notched alginate–PAAm hydrogel reinforced with stretchy thermoplastic-elastomer fibers (A∥ = 1.93%, A⊥ = 4.07%). The critical stretches obtained from the notched samples are marked on the curves as crosses. For comparison, we also measure the stress–stretch curves of two control samples: the alginate–PAAm hydrogel without fiber reinforcement, and the hydrogel reinforced with rigid but relatively brittle PLA (polylactic acid, MakerBot, US) fibers. As shown in Fig. 3a, the hydrogel reinforced with thermoplastic-elastomer fibers can indeed provide relatively high values of the modulus (1.4 MPa), toughness (8554 J m−2) and stretchability (λc ≈ 2.80 for the notched sample). In comparison, the hydrogel reinforced with brittle PLA fibers has a high modulus but relatively low toughness (967 J m−2), because the stiff but brittle fibers are fractured at a very low stretch (λc ≈ 1.09 for the notched sample). On the other hand, the hydrogel without fiber reinforcement is highly stretchable (λc ≈ 19 for the notched sample) but its modulus is very low (70.0 kPa). Therefore, the design of stiff, tough and stretchy hydrogels in the current study relies on a combination of the stiff yet stretchy fiber mesh and the tough hydrogel matrix. Furthermore, the strengthening of the composite indeed relies on multiple mechanisms across multiple length scales (Fig. 1a and Table 1).
We further vary the area fraction of stretchy thermoplastic-elastomer fibers along the direction of the applied force (A∥ = 0.94–7.69%), while maintaining the area fraction of orthogonal fibers constant (A⊥ = 4.07%). From Fig. 3b it can be seen that as the fiber density increases, the modulus and yield stress of the composite increase, and the critical stretch maintains in the range of 2.8 to 3.8. The yield stretch of the thermoplastic-elastomer fiber mesh is ∼1.4, below which the fiber-reinforced hydrogel can be repeatedly stretched and un-stretched multiple cycles without inducing permanent deformation or damage of the sample (Fig. 3c). Hysteresis loops can also be observed on the loading–unloading curves over multiple cycles, potentially due to viscoelasticity of the thermoplastic-elastomer fibers and reversible crosslinking in the hydrogel matrix. The repeated hysteresis loop over multiple loading–unloading cycles is a critical character of anti-fatigue hydrogels.15,31,32
The measured modulus, yield stress, and fracture energy of the alginate–PAAm hydrogel reinforced with various densities of fiber meshes are shown in Fig. 5. As the area fraction of fibers along the applied force A∥ increases from 0.94% to 7.69%, the plane-strain Young's modulus of the composite increases from 0.66 to 6.37 MPa, the yield stress from 115 to 753 kPa, and the fracture toughness from 6360 to 33
000 J m−2, while the critical stretch remains relatively constant, in the region as 2.8–3.8.
| Ē = A∥Ef + (1 − A∥)Ēg | (3) |
Similarly, the plane-strain yield (nominal) stress of the fiber-reinforced hydrogel can be predicted as
![]() | (4) |
is the nominal stress in an un-notched pure hydrogel under the pure shear test at the yield stretch of the fiber λYf ≈ 1.4 (Fig. S3b†).
Fracture energy of fiber-reinforced materials generally consists of contributions from the fiber mesh, the matrix, and friction between the matrix and fibers. In the current study, since the fibers debond from the hydrogel at moderate deformation, we neglect the fracture energy due to friction between fibers and the hydrogel matrix. Furthermore, in measuring the fracture energy, we regard the stretch when the crack begins to propagate in the fiber mesh as the critical stretch, λc. Therefore, the fracture energy of the fiber-reinforced hydrogel is a summation of the fracture energy of the fiber mesh and the work done to stretch the hydrogel matrix to λc in the pure shear test, i.e.
![]() | (5) |
![]() | (6) |
is the work of extension of a single fiber in the fiber mesh, δ⊥ gives a typical length scale of the fiber mesh, and α is a function of δ∥/δ⊥ and the constitutive law of a single fiber. The curve of sfvs. λf of a single fiber is shown in Fig. S3b,† where the fracture stretch of a single fiber λcf and the work of extension
have been measured to be 5 and 51
700 J m−3, respectively.
From eqn (5) and (6), we can see that the fracture energy of the fiber-reinforced hydrogel can be predicted based on the measured stress vs. stretch relationship of a pure hydrogel and a single fiber (Fig. S3†), given the non-dimensional parameter α. In order to calculate α, we construct a finite-element model of a notched fiber mesh, which undergoes the pure-shear test, using the software package ABAQUS 6.10. The fiber meshes of different geometries (i.e., δ∥/δ⊥ = 0.5, 1, 2, 4; and H/δ⊥ = 3, 5, 7, 9, 11) are modeled with beam elements. Following the experimental setup, one edge of the model is fixed and the opposite edge of the model is subjected to a prescribed vertical displacement. Mesh insensitivity of the model is verified by uniformly reducing the element sizes: no significant change in the calculated structural response is observed. Since unloading of the fiber mesh is not considered in the model,33 the elastoplastic fiber can be taken as a hyperelastic material that follows the stress vs. stretch relationship shown in Fig. S3b.†
In the calculation, as the stretch in the fiber segment right in front the notch reaches λcf (i.e., the fiber segment begins to fracture), and the stretch of the fiber mesh is recorded as the critical stretch, λc (Fig. 2b). Considering the pure-shear test, the fracture energy of the fiber mesh can also be calculated as
. Further considering eqn (6), we can express the non-dimensional parameter α as
![]() | (7) |
In Fig. 5d, we further compare the fracture energies and moduli of various types of synthetic hydrogels reported in the literature.2,13 It can be seen that the fracture energy of conventional hydrogels is usually below 100 J m−2, with moduli below 100 kPa. Tough hydrogels that rely on a single pair of toughening mechanisms can reach fracture energies up to 10
000 J m−2 and moduli up to 1 MPa (Fig. 5d and Table 1). By comparison, the stretchy-fiber-reinforced hydrogel developed in the current study can reach a fracture energy over 33
000 J m−2 and a modulus over 6 MPa.
We then discuss the robustness of hydrogels under environmental loads. Since the stretchy-fiber-reinforced hydrogel integrated multiple pairs of toughening mechanisms (Table 1), it can still maintain its high toughness even when some of the mechanisms become invalid. For example, we soak the fiber-reinforced PAAm–alginate hydrogel in 2% EDTA (ethylenediamine tetraacetic acid) (in 1 M NaOH, which is 1 Normality NaOH) to chelate Ca2+ in the hydrogel matrix, which eliminates the dissipation mechanism of reversible crosslinking (Fig. S4a†). However, since the viscoelasticity and plasticity of the fiber mesh can still dissipate the mechanical energy under deformation, the resultant fiber-reinforced hydrogel without Ca2+ can still reach an impressively high modulus of ∼6.7 MPa and a toughness of ∼30
000 J m−2 (Fig. S4a† and Table 1). In comparison, we also soak a PAAm–alginate hydrogel without fiber reinforcement in 2% EDTA (ethylenediamine tetraacetic acid) (in 1 M NaOH). Due to the loss of the only dissipation mechanism in the hydrogel, the resultant hydrogel indeed becomes weaker with a fracture energy reduced from 9000 J m−2 to 400 J m−2 (Fig. S4b† and Table 1).
In addition, the fiber-reinforced hydrogel can be easily printed and cast into various shapes for potential applications in biomedical and robotic areas.3,8,34,35 For example, in Fig. S5a,† we demonstrate an artificial intervertebral disc made of the fiber-reinforced hydrogel. The inner part of the artificial intervertebral disc consists of a pure PAAm–alginate hydrogel to approximate the relatively compliant nucleus pulposus, which is surrounded by the fiber-reinforced hydrogel to approximate the relatively stiff annulus fibrosus. We further compare the force vs. displacement curves of artificial intervertebral discs made of the fiber-reinforced hydrogel, PAAm–alginate and PAAm hydrogels without fiber reinforcement (Fig. S5b†). It can be seen that, by using the stretchy-fiber reinforcement, we can indeed tune the overall stiffness of the artificial intervertebral disc over a wide range, while maintaining the high toughness of the hydrogel.
In this paper, we integrate nanoscale hybrid crosslinking and macroscale fiber reinforcement to develop a novel hydrogel with an unprecedented set of mechanical properties including a high toughness (>33
000 J m−2), a high modulus (>6 MPa), and a high stretchability (>2.8 with a notch). Theoretical and computational models are further developed to predict the mechanical properties and guide the design of the new hydrogels. The combined experimental and theoretical results show that the toughness, modulus and yield stress of the new hydrogel can be uniformly increased by rational design of the stretchy-fiber mesh and the tough hydrogel matrix. Due to the multi-scale multi-mechanism strengthening, the new hydrogel is more robust against mechanical and environmental loads than conventional tough hydrogels. In addition, the fiber mesh can be printed into various shapes with commercially available 3D printers, on which the tough hydrogel matrix can be cast. The combined theoretical and experimental study opens up new avenues to both fundamental understanding and practical applications of hydrogels with extraordinary properties.
Footnote |
| † Electronic supplementary information (ESI) available. See DOI: 10.1039/c4sm01039f |
| This journal is © The Royal Society of Chemistry 2014 |