Bicontinuous Structure Research Articles

Liquid-solid phase separation and recycling of permalloys in liquid Mg

Liquid-solid phase separation of permalloy in liquid Mg results in selectively dissolved Ni, which provides a unique opportunity for the design of immiscible heterogeneous composite materials and the comprehensive metal recycling of permalloy scraps. A guideline of the alloy design for the liquid-solid phase separation system was proposed. The effects of immersion temperature and time on the Ni extraction were studied by an experimental method. The diffusion behavior of Ni from the permalloy to liquid Mg and the microstructure evolution in the permalloy during the liquid-solid phase separation were discussed. The results show that the Ni in the permalloy was quickly extracted into the liquid Mg and formed an Mg-Ni alloy, while the other components such as Fe, Co, and Mn were held back in the phase-separated permalloy. The phase-separated permalloy with the solidified Mg exhibits a three-dimensional (3D) Fe/Mg bicontinuous composite structure. Furthermore, simple treatments were carried out for the reaction products such as the Fe/Mg bicontinuous composite and the Mg-Ni alloy, and the recycling strategies for functionalization of these treated reaction products were provided. A 3D porous Fe-based alloy with electromagnetic interference (EMI) shielding efficiency of 52 dB can be obtained if Mg is removed from the Fe/Mg bicontinuous composite. Instead of the complete separation of pure Ni from the recycled Mg-Ni alloy by vacuum distilling, the Mg-Ni alloy can be enriched into Mg2Ni as an initial hydrogen storage material.

Impact of water and oleic acid on glycerol monooleate phase transition and bi-continuous structure formation in white oil.

Production of biofuels from biological feedstocks, such as soybean oil, is an important piece of the transition to renewable energy sources. Processes have been developed to co-refine these feedstocks with traditional feedstocks, however, the high concentration of polar functional groups in biofeedstocks can cause a wide range of intermediate chemical reactions and interactions. An improved understanding of the interactions of biofeedstocks and their degradation products is needed to continue to expand the usage of biofeedstocks in fuel production. In this study, the equilibrium structures of glycerol monooleate (GMO), a common intermediate product of biofeedstock processing, in white mineral oil at a wide range of compositions, temperatures, and additional byproduct concentrations (water and/or oleic acid) were characterized using small angle X-ray scattering (SAXS). It was determined that GMO can exist as crystalline aggregates in white oil or as reverse micelles depending on the concentration and temperature. The critical micelle temperature increases significantly with increasing GMO concentration but remains relatively stable with increasing water or fatty acid concentration. Fitting of the SAXS data revealed that for many compositions, the GMO formed roughly spherical reverse micelles, however, at high water concentrations (∼1 wt%), the GMO formed elongated reverse micelles. Additionally, when >1 wt% oleic acid was added to the system, bi-continuous structures were stabilized rather than discreet reverse micelles. These results help increase our understanding of the structural behavior of biofeedstock intermediate products at concentrations and temperatures relevant to biofuel production and can enable processers to design systems and products that can either leverage or prevent these interactions for improved processing performance.

Towards data-efficient mechanical design of bicontinuous composites using generative AI

The distribution of material phases is crucial to determine the composite's mechanical property. While the full structure-mechanics relationship of highly ordered material distributions can be studied with finite number of cases, this relationship is difficult to be revealed for complex irregular distributions, preventing design of such material structures to meet certain mechanical requirements. The noticeable developments of artificial intelligence (AI) algorithms in material design enables to detect the hidden structure-mechanics correlations which is essential for designing composite of complex structures. It is intriguing how these tools can assist composite design. Here, we focus on the rapid generation of bicontinuous composite structures together with the stress distribution in loading. We find that generative AI, enabled through fine-tuned Low Rank Adaptation models, can be trained with a few inputs to generate both synthetic composite structures and the corresponding von Mises stress distribution. The results show that this technique is convenient in generating massive composites designs with useful mechanical information that dictate stiffness, fracture and robustness of the material with one model, and such has to be done by several different experimental or simulation tests. This research offers valuable insights for the improvement of composite design with the goal of expanding the design space and automatic screening of composite designs for improved mechanical functions.

A natural multifunction and multiscale hierarchical matrix as a drug-eluting scaffold for biomedical applications.

Sea urchin spines are biogenic single crystals of magnesium calcite that are stiff, strong, damage tolerant and light and have a bicontinuous porous structure. Here, we showed that the removal of their intraskeletal organic matrix materials did not affect the compressive mechanical properties and generated an open porosity. This matrix was able to adsorb and release oxytetracycline, a broad-spectrum antibiotic. The drug-loaded sea urchin matrix induced bacterial cell death after 4 and 8 hours of incubation of both Gram-negative E. coli and Gram-positive S. aureus strains and this process induces an inhibition of bacterial cell adhesion. In conclusion, this study shows that thermally treated sea urchin spines are a compressive resistant and lightweight matrix able to load drugs and with potential use in spine fusion, a challenging application that requires withstanding high compressive loading.

Self-assembly of single-chain nanoparticles from block copolymers into inverse bicontinuous structures

Single-chain nanoparticles preferentially self-assemble into cubosomes with a broad window by intrachain cross-linking the hydrophilic chains of block copolymers, which accounts for the smaller a0 and the larger P.

Corrosion Behavior of Binary Ni-Cr Alloys in Molten FLiNaK Salts at Different Electrochemical Potentials

The development of molten salt reactors (MSRs) is a collaborative effort among academia, government laboratories, and industry, with the aim of realizing the potential of clean nuclear energy. However, the corrosion of structural alloys presents a significant engineering challenge in this application. Addressing this issue requires investment not only in testing and characterizing candidate alloys, but also in developing a scientific framework to understand the fundamental mechanisms governing the corrosion of metallic materials in molten fluorides which can then guide alloy design [1].In this work, the corrosion behavior of binary Ni-Cr alloys (5-20 wt.% Cr) in molten LiF-NaF-KF (or FLiNaK) salts between 550oC and 750oC was interrogated using electrochemical methods coupled with thermo-kinetic analysis. Electrochemical techniques, including linear sweep voltammetry, electrochemical impedance spectroscopy (EIS) and chronoamperometry, were utilized to elucidate the rate-limiting kinetic factors and to identify the dependence of corrosion morphology on applied potential. Additionally, Ni-Cr alloys were also immersed 99.9% pure FLiNaK salts with a known oxidizer concentration (e.g., 0.1-5 wt.% EuF3) coupled with open-circuit potential measurement to provide a time-based description of morphological evolution in the case of a dynamically changing electrode potential. These results are corroborated by examination of the post-corrosion morphology using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and electron backscatter diffraction (EBSD) techniques as well as salt composition analysis using inductively coupled plasma mass spectrometry (ICP-MS), X-ray diffraction (XRD) and in situ cyclic voltammetry.The systematic choice of potential revealed multiple potential regimes in which Ni-Cr alloys exhibit distinctly different corrosion morphologies. At intermediate potentials, a porous bicontinuous structure is formed by dealloying of the less noble element (Cr) and percolation into the Ni-rich alloy within grains and along grain boundaries. At other potentials, charge transfer control dissolution of both Cr and Ni leads to the formation of a crystallographic faceted structure. The morphological differences suggest the presence of multiple corrosion processes in Ni-Cr in FLiNaK controlled by either transport or interfacial reaction. These findings can be explained through electrochemical processes at the alloy-salt interface, as well as the roles of surface, grain boundary and bulk diffusion kinetics involving the alloying constituents. Furthermore, the effect of radiation damage on Ni20Cr alloys on these rate-limiting corrosion regimes will be investigated. Acknowledgment Research is primarily supported as part of the fundamental understanding of transport under reactor extremes (FUTURE), an Energy Frontier Research Center (EFRC) funded by the U.S. Department of Energy (DOE), Office of Science, Basic Energy Sciences (BES).[1] Chan, H.L., et al. Npj Materials Degradation 6(1), 46 (2022).

Study on the Properties Changes of Reversible Invert Emulsion during the Process from O/W to W/O with Alkali.

The reversible emulsion drilling fluid system combines the advantages of both oil-based and water-based drilling fluids, which can achieve ideal results in different stages of drilling and completion, and the system can be reused to effectively reduce costs. However, the research on reversible emulsions mainly focuses on the development of new reversible emulsifiers, while the specific phase transformation mechanism of reversible emulsion systems is still unclear. In this paper, a stable reversible emulsion was prepared using the reversible emulsifier DMOB as a raw material, and the reversible emulsion performance of the alkali response from the O/W emulsion phase to the W/O emulsion was studied. The microstructure of reversible emulsions was studied by a microscope, a cryogenic transmission electron microscopy, and a laser particle size analyzer. The changes in macroscopic properties of reversible emulsions in the process of alkali conversion were studied by pH, conductivity, demulsification voltage, static stability, viscosity, rheology, and other indicators, and the conversion mechanism of reversible emulsions from O/W emulsion ⟶ bicontinuous structure ⟶ O/W/O emulsion ⟶ W/O emulsion was clarified. The details are as follows: in the first stage, when the amount of NaOH ≤ 0.43 vol.%, the overall particle size of the emulsion decreases first and then increases with the increase in NaOH dosage. In the second stage, when the amount of NaOH was 0.45 vol.%, a double continuous structure was formed inside the emulsion. In the third stage, when the amount of NaOH is 0.48 vol.%, the O/W/O emulsion is formed, and with the increase in stirring time, the internal oil droplets gradually accumulate and are discharged from the water droplets, and finally, the W/O emulsion is formed. In the fourth stage, when the dosage of 0.50 vol.% ≤ NaOH ≤ 5.00 vol.%, the W/O emulsion was formed, and with the increase of NaOH dosage, the structure and compactness between water droplets increased first and then decreased. In the whole process, with the increase in the amount of NaOH solution, the total particle size of the emulsion first decreased and then increased.

Aquatic Functional Liquid Crystals: Design, Functionalization, and Molecular Simulation.

Aquatic functional liquid crystals, which are ordered molecular assemblies that work in water environment, are described in this review. Aquatic functional liquid crystals are liquid-crystalline (LC) materials interacting water molecules or aquatic environment. They include aquatic lyotropic liquid crystals and LC based materials that have aquatic interfaces, for example, nanoporous water treatment membranes that are solids preserving LC order. They can remove ions and viruses with nano- and subnano-porous structures. Columnar, smectic, bicontinuous LC structures are used for fabrication of these 1D, 2D, 3D materials. Design and functionalization of aquatic LC sensors based on aqueous/LC interfaces are also described. The ordering transitions of liquid crystals induced by molecular recognition at the aqueous interfaces provide distinct optical responses. Molecular orientation and dynamic behavior of these aquatic functional LC materials are studied by molecular dynamics simulations. The molecular interactions of LC materials and water are key of these investigations. New insights into aquatic functional LC materials contribute to the fields of environment, healthcare, and biotechnology.

Phase-Pinned Bicontinuous Structures Reconciling with the Superior Fracture Toughness and Reusability of Ionic Elastomers

Phase-Pinned Bicontinuous Structures Reconciling with the Superior Fracture Toughness and Reusability of Ionic Elastomers

Unique bi-continuous phase structure can facilitate the development of fire-resistant surface

Selectively localizing flame retardants and smoke suppressants on the surface can maintain fire resistance properties and other bulky properties while reducing additives usage. However, achieving this with traditional processing techniques remains challenging. In this work, taking immiscible polyvinyl chloride (PVC), ethylene–vinyl acetate (EVA) and expanded graphite (EG) as an example, we attempted to localize EG within single or dual polymer phases, culminating in the development of three bi-continuous ternary composite systems. It was interesting to find that selective EG localization in EVA phase (low smoke emission) gave rise to a distinct fire-resistant surface, showcasing the highest flame retardancy (limiting oxygen index), smoke suppression properties (both experimental and simulation data), mechanical properties, and thermal stability. The formation of such functional surface was attributed to the distinct rheological behaviors between EVA/EG and PVC. These inspiring results proved that the combination of flame retardants/smoke suppressants with a low-smoke-emission polymeric phase in bi-continuous composite systems could create fire-resistant surface via tuning rheological characters, which stands out as universal, efficient, simple, and green methodology compared to more complex synthetic surface chemistry approaches.

Dual PVP roles for preparing PVDF hollow fiber membranes with bicontinuous structures via the complex thermally induced phase separation (c-TIPS)

Polyvinylpyrrolidone (PVP) is a widely used water-soluble polymer that can act as a pore-forming additive in ultrafiltration membrane preparation. Here, the PVDF hollow fiber membranes were prepared via the c-TIPS method by introducing PVP to the casting solution. The dual PVP roles in the membrane fabrication process enabled the production of PVDF hollow fiber membranes composed of bicontinuous structures. The PVP inhibited PVDF crystallization and then reduced the gelation temperature of the casting solution. They grew faster at coarsening, allowing greater growth of pores, and the formation of gap-connected pores and interlinked pores, which formed the bicontinuous structure. The PVP also acted as an effective pore-forming agent, giving porous outer surface. PVP can be removed almost completely from the membrane and did not lead to the wetting of PVDF membranes. Therefore, the synthesized PVDF membrane under optimal conditions could be used in the DCMD process with a maximum vapor flux of 18 ± 3 kg m−2 h−1, the pure water flux in ultrafiltration process reached 335.91 L m−2 h−1 bar−1, and the tensile stress was 5.8 MPa. This work presents a new route for preparing PVDF hollow fiber membranes using conventional spinning equipment with simple operation and moderately elevated temperature that is scalable to industry level.

Causal structure of spacetime and Scott topology

In this paper we establish the spacetime manifold as a partially ordered set via the casual structure. We show that these partially ordered sets are naturally continuous as a suitable way below relation can be established via the chronological order. We further consider those classes of spacetimes on which a lattice structure can be endowed by physically defining the joins and meets. By considering the physical properties of null geodesics on the spacetime manifold we show that these lattices are necessarily distributive. These lattices are then continuous as a result of the equivalence between the way below relation and chronology. This enables us to define the Scott topology on the spacetime manifold and describe it on an equal footing as any other continuous lattice. We further show that the Scott topology is a proper subset of Alexandroff topology, which must be the manifold topology for the strongly causal spacetimes, (and hence a coarser topology than Alexandroff). In the process we find some interesting results on the sobriety of these manifolds. We prove that they are necessarily not sober under the Scott topology but regain their sobriety under Alexandroff topology. We also define a dual Scott topology on these manifolds by endowing them with bicontinuous poset structure and show that the join of the Scott topology with the dual is the Alexandroff topology. We also discuss the previous works done in this topic and how the present work generalises those results to some extent.

Bi-Continuous Si/C Anode Materials Derived from Silica Aerogels for Lithium-Ion Batteries

Poor cycling performance caused by massive volume expansion of silicon (Si) has always hindered the widespread application of silicon-based anode materials. Herein, bi-continuous silicon/carbon (Si/C) anode materials are prepared via magnesiothermic reduction of silica aerogels followed by pitch impregnation and carbonization. To fabricate the expected bi-continuous structure, mesoporous silica aerogel is selected as the raw material for magnesiothermic reduction. It is successfully reduced to mesoporous Si under the protection of NaCl. The as-obtained mesoporous Si is then injected with molten pitch via vacuuming, and the pitch is subsequently converted into carbon at a high temperature. The innovative point of this strategy is the construction of a bi-continuous structure, which features both Si and carbon with a cross-linked structure, which provides an area to accommodate the colossal volume change of Si. The pitch-derived carbon facilitates fast lithium ion transfer, thereby increasing the conductivity of the Si/C anode. It can also diminish direct contact between Si and the electrolyte, minimizing side reactions between them. The obtained bi-continuous Si/C anodes exhibit excellent electrochemical performance with a high initial discharge capacity of 1481.7 mAh g−1 at a current density of 300 mA g−1 and retaining as 813.5 mAh g−1 after 200 cycles and an improved initial Coulombic efficiency of 82%. The as-prepared bi-continuous Si/C anode may have great potential applications in high-performance lithium-ion batteries.

Tailoring the oral sensation and digestive behavior of konjac glucomannan-gelatin binary hydrogel based bigel: Effects of composition and ratio

In the food industry, there is a growing demand for bigels that offer both adaptable oral sensations and versatile delivery properties. Herein, we developed bigels using a binary hydrogel of konjac glucomannan (KGM) and gelatin (G) combined with a stearic acid oleogel. We closely examined how the oleogel/hydrogel volume ratio (φ) and the KGM/G mass ratio (γ) influenced various characteristics of the bigels, including their microstructure, texture, rheological properties, thermal-sensitivity, oral tribology, digestive stability, and nutraceutical delivery efficiency. A noteworthy observation was the structural evolution of the bigels with increasing φ values: transitioning from oleogel-in-hydrogel to a bicontinuous structure, and eventually to hydrogel-in-oleogel. Lower γ values yielded a softer, thermally-responsive bigel, whereas higher γ values imparted enhanced viscosity, stickiness, and spreadability to the bigel. Oral tribology assessments demonstrated that φ primarily influenced the friction sensations at lower chewing intensities. In contrast, γ played a significant role in augmenting oral friction perceptions during more intense chewing. Additionally, φ dictated the controlled release and bioaccessibility of curcumin, while γ determined digestive stability. This study provides valuable insights, emphasizing that through meticulous selection and adjustment of the hydrogel matrix composition, bigels can be custom-fabricated to achieve specific oral sensations and regulated digestive behaviors.

Development of 3D bicontinuous metal–intermetallic composites through subsequent alloying process after liquid metal dealloying

This study presents a novel process for the fabrication of metal–intermetallic composites with a 3D bicontinuous structure, achieved through a combination of liquid metal dealloying (LMD) and subsequent alloying. Initially, porous Ti structures are produced using the LMD process, followed by immersion in a molten Mg–3Al (wt%) metal. Due to the higher thermodynamic miscibility of Al with Ti compared to Mg, the concentration of Al in the Ti matrix increases as the immersion time increases. This results in a sequential phase transition within the Ti matrix: α-Ti → Ti3Al → TiAl. The phase transition considerably affects the hardness and strength of the composite material, with the Mg–Ti3Al–TiAl composite exhibiting a maximum hardness nearly twice as high as that of the conventional Mg–Ti composite. This innovative process holds potential for the development of various bicontinuous metal–intermetallic composites.

Carbonized Leather Waste with Deposited Polypyrrole Nanotubes: Conductivity and Dye Adsorption.

This paper reports the conversion of a waste to a conducting material, exploiting the ability to adsorb pollutant organic dyes. Leather waste was carbonized at 800 °C in an inert nitrogen atmosphere. The resulting biochar was used for in-situ deposition of polypyrrole nanotubes produced by the oxidative polymerization of pyrrole in the presence of methyl orange. The composites of carbonized leather with deposited polypyrrole nanotubes of various composition were compared with similar composites based on globular polypyrrole. Their molecular structure was characterized by infrared and Raman spectra. Both conducting components formed a bicontinuous structure. The resistivity was newly determined by a four-point van der Pauw method and monitored as a function of pressure applied up to 10 MPa. The typical conductivity of composites was of the order of 0.1 to 1 S cm-1 and it was always higher for polypyrrole nanotubes than for globular polypyrrole. The method also allows for the assessment of mechanical features, such as powder fluffiness. The conductivity decreased by 1-2 orders of magnitude after treatment with ammonia but still maintained a level acceptable for applications operating under non-acidic conditions. The composites were tested for dye adsorption, specifically cationic methylene blue and anionic methyl orange, using UV-vis spectroscopy. The composites were designed for future use as functional adsorbents controlled by the electrical potential or organic electrode materials.

Tailoring stimuli-responsive PVDF-based copolymer membrane with engineered pore structure for efficient antibody purification

Membrane chromatography is considered as a sustainable alternative for downstream purification to overcome the production bottleneck of biopharmaceuticals. However, two of the major factors impeding its industrial adoption are the lack of controllable functionalization and competitive binding capacity. This work aimed to develop a one-pot synthesis strategy for fabricating a new class of pH-responsive poly(vinylidene fluoride)-graft-poly(dimethylaminoethyl methacrylate) (PVDF-g-PDMAEMA) membranes with anion exchangers, to achieve fast and accurate removal of albumin impurities from antibody streams. By utilizing a pre-functionalized copolymer with controlled ligand density, PVDF-g-PDMAEMA membranes with advantageous bicontinuous pore network structure were obtained via an unconventional nonsolvent thermally induced phase separation method. The membrane showed a competitive water permeance of > 6000 L m-2h−1 bar−1. Combining with dedicated static binding and isotherm studies, the membranes demonstrated distinct pH-responsive binding behaviour to model impurity bovine serum albumin (BSA) with maximal binding of 318.0 mg/g at pH 5.5. The dynamic flow-through binding experiments indicated that the membrane could effectively capture BSA from immunoglobulin G (IgG) (model antibody)/BSA mixed solution with a competitive binding capacity of 210.5 mg/g, producing IgG with purity > 90 % and nearly full recovery. Also, comprehensive analysis demonstrated the robustness of the membrane performance through five consecutive operation cycles, with or without harsh alkaline regeneration. The biocompatibility analysis further proved the membranes’ suitability in biopharmaceutical applications. This study provided a new route for designing future chromatographic membranes to promote its industrial uptake, pushing for energy-saving and effective downstream bioprocessing.

Preparation of toughened thermal insulating polylactic acid/thermoplastic polyester elastomer (TPEE) microcellular foam using in situ fibrillation and multi-hydrazide nucleating agent self-assembly

Traditional foamed plastics can no longer meet the requirements of modern industries. High-performance biodegradable thermal-insulation materials are required for the food transportation and packaging industry. In this study, we introduced the synergistic self-assembly effect of nanoelastic (TPEE) fibers and TMC-300 (sebacic acid diphenyl hydrazide) through an in situ fibrosis to control the crystal morphology and phase structure. This effect improves the melt viscoelasticity of branched polylactic acid (CBPLA) and improves the foaming performance of PLA. The sea-island structure of PLA composites was transformed into an imperfect bi-continuous structure and its toughness was improved without the loss of PLA stiffness. Further, the toughness of the CBPLA/TMC/TPEE composite was improved by 76%, the thermal stability was significantly improved, and there was no effect on the tensile strength. CBPLA/TMC/TPEE microcellular foams were successfully prepared using supercritical CO2 in an intermittent high-pressure foaming autoclave with average cell diameter of 4 μm. The cell density of CBPLA foam was increased by 3 orders of magnitude compared to that of pure PLA foam, average cell diameter successfully reduce from 34 μm to 4 μm. The thermal conductivity of air in the micron-sized cells was reduced significantly, and therefore, the microcellular foam showed excellent thermal insulation performance with a thermal conductivity as low as 25.2 mW/mK. The TPEE/TMC elastic self-assembled fiber network dispersed on the cell wall cooperatively supported the PLA cell wall, which significantly improved the compressive resistance of PLA foams; the compression rebound rate of the foam was approximately 34%. The results indicate that CBPLA/TMC/TPEE microcellular foam materials are potential candidates for high-performance thermal applications because of their excellent thermal stability, toughness, and thermal insulation performance.

Breaking the trade-off between selectivity and permeability of nanocomposite membrane modified by UIO66@PDA through nonsolvent thermally induced phase separation method

Developing polymer membranes with high permeability, fouling resistance, and rejection capability is a challenging task that requires the use of novel materials to enhance these properties. In this study, composite ultrafiltration membranes were fabricated by incorporating two types of metal–organic frameworks (MOFs), UIO66 and UIO66@PDA, into polyvinylidene fluoride (PVDF) using the nonsolvent thermally induced phase separation (NTIPS) method. The results demonstrated that the NTIPS method combined the characteristics of nonsolvent-induced phase separation (NIPS) and thermally induced phase separation (TIPS) to fabricate asymmetric membranes with a dense ultra-thin top layer and a bicontinuous network structure. Moreover, the introduction of 1.0 wt% UIO66@PDA into PVDF membranes yielded notable improvements in mechanical strength, thermal stability, and porosity. Concurrently, this led to a water flux rise from 182.5 to 464.7 L·m−2·h−1, and enhanced BSA and HA rejection to 96% and 83%, respectively. Additionally, there was a significant improvement in the membrane's antifouling capacity, achieving a water flux recovery ratio of 93%. This was facilitated by the increased hydrophilicity of UIO66@PDA, which attracted more water molecules and reduced membrane fouling. This work offers a solution to overcome the permeability-selectivity trade-off in membrane separation by hydrophilic modification of hydrophobic membranes, while also addressing fouling issues.

Low‐cost and high‐performance poly(butylene adipate‐co‐terephthalate)/thermoplastic starch blends prepared by an eccentric rotor extruder: Morphology, rheological behavior, thermal and mechanical properties

AbstractDue to similar processing and mechanical properties, poly(butylene adipate‐co‐terephthalate) (PBAT) is expected to be a fully‐biodegradable alternative to low‐density polyethylene (LDPE) packaging films, thereby alleviating environmental pollution caused by waste packaging films. However, the higher price of PBAT limits its large‐scale practical application in the packaging field. Blending with thermoplastic starch (TPS) to prepare PBAT/TPS blends can reduce the cost. In this work, the PBAT/TPS blends with different compositions were prepared using a novel eccentric rotor extruder dominated by an extensional flow field. With increasing the TPS content, a transition from the sea‐island phase structure to the bicontinuous phase structure occurred near the composition ratio of 50/50. Moreover, the dynamic mechanical analysis results showed that the compatibility between PBAT and TPS first improved and then deteriorated as the TPS content increased. As a result, the elongation at break first decreased slightly from ~1585% for the PBAT/TPS(90/10) blend to ~1263% for the PBAT/TPS(70/30) blend and dropped sharply to ~130% for the PBAT/TPS(40/60) blend. The knowledge obtained from this study will help us further understand the effect of the TPS phase on the micro‐morphology and macro‐properties of the PBAT/TPS blends, which is important for the future preparation of high‐performance PBAT/TPS blends.