Polyvinyl alcohol (PVA) and chitosan (CS) are biopolymers with immense potential in packaging and biomedical applications, along with water purification due to their biodegradability and structural advantages. However, their inherent mechanical limitations hinder broader applicability. Here we report the enhancement in mechanical properties of PVA/CS hybrid films by optimizing polymer concentrations, coagulation solvents, and crosslinking conditions. FTIR analysis revealed successful crosslinking, with characteristic peaks for PVA’s –OH stretching (2800–3200 cm⁻1) and CS’s amide II vibrations (1555 cm⁻1). Glutaraldehyde (GA) crosslinking introduced aldehyde C=O (1634 cm⁻1) and O-H (3341 cm⁻1) peaks, strengthening the matrix. XRD analysis showed diminished CS crystallinity (reduced peak at 8.63°) due to crosslinking, while new semi-crystalline peaks at 10° and 12° and crystalline peaks at 35° and 42° contributed to a crystallinity index of 0.740. Mechanical properties improved significantly with heat treatment, improving Young’s modulus above 232.76 MPa, enhancing tensile strength, waterproofing, and crystalline fraction. NaOH treatment further strengthened the films due to hydroxide functionalization, improving intermolecular interactions. The material exhibits thermal stability up to 218°C, with major decomposition due to polymer and saccharide ring degradation occurring at higher temperatures (472–553°C). The different characterizations of the optimized PVA/CS films exhibit successful PVA/CS film formation with enhanced mechanical integrity, thermal stability, and biodegradability, with the 3% PVA and 1% CS combination emerging as the best formulation, offering a sustainable alternative to synthetic polymers for diverse environmentally focused applications.
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