Poly(arylene ether sulfone)s (PAES) are important commercial polymers and have been extensively studied due to their excellent thermal and mechanical properties. However, some applications are still limited when good solvent resistance and low thermal expansion coefficient are required. There has been a continuous interest in developing new PAES based on new monomers or polymer modifications to obtain new properties or to enhance existing properties. In this dissertation, the synthesis, characterization and structure-property relationship of new 1,4-cyclohexylene ring containing PAESs were comprehensively studied. Different polymerization techniques were used to synthesize polymers with different segmental lengths. The monomer, 4,4'-[trans-1,4-cyclohexanebis(methylene)] bisphenol (CMB), was synthesized and fully characterized. Based on 4,4′-dihydroxy-p-terphenyl (DHTP), 4,4′-dihydroxybiphenyl (DHBP) and the CMB monomer, homopolymer and random copolymers of PAES were prepared with high molecular weights and high glass transition temperatures. Dynamic mechanical analysis (DMA) on these polymers showed multiple sub-Tg relaxations. A large increase in the ultimate elongation was obtained with the CMB and DHTP containing sample, which could be due to the strong sub-Tg relaxations observed from the DMA results. A series of four acid chloride monomers were synthesized and polymerized with phenol terminated PAES oligomers. Solution polymerization and pseudo-interfacial polymerization techniques were used to prepare both bisphenol-A (bis-A) based and DHBP based PAES oligomers. With the incorporation of the trans-1,4-cyclohexylene units, decreases in the glass transition temperatures were observed from both the bis-A based and the DHBP based polymers. However, melting transitions were only observed in the DHBP based trans-1,4-cyclohexylene containing PAESs. Crystallinity was confirmed by differential scanning calorimetry (DSC) and wide angle X-ray diffraction (WAXD). A mechanical property study of the high molecular weight trans-1,4-cyclohexylene containing polymer samples showed moderate ultimate elongation enhancements. A series of PAES-polyester multiblock copolymers were synthesized with both solution method and melt polymerization. In the solution method, phenol terminated PAES oligomers and the acid chloride terminated poly(1,4-cyclohexylenedimethylene terephthalate) (PCT) oligomers were presynthesized and coupled in solution. The molecular weights of the polymer products obtained from the solution method were limited by solubility issues. Melt phase polymerization was employed to obtain high molecular weight polymers. Hydroxy ethoxy terminated PAES oligomers were synthesized and polymerized with 1,4-cyclohexanedimethanol (CHDM) and dimethyl terephthalate (DMT) in the melt. Polymers with high molecular weights were obtained. Tensile test results suggested that the mechanical properties of these polymers were dominated by the PAES components with polyester contents up to 20 wt%. Melting transitions were observed from polymers with higher polyester contents, and these polymers exhibited limited solubility in common organic solvents. / Ph. D.

Poly(arylene ether sulfone)s with dendritic terminal groups were synthesized by step-growth polymerization of two difunctional monomers in the presence of preformed dendritic end-cappers. These polymers were characterized by NMR, SEC, DSC, TGA, melt rheology and tensile tests. The melt viscosities of these polymers in the high frequency region were lower than the control while the stress-strain properties were comparable to those of the control, suggesting that it is possible to reduce the high shear melt viscosities of this type of polymers without affecting the stress-strain properties by introducing bulky dendritic terminal groups. Poly(arylene ether sulfone)s with hyperbranched terminal groups were also synthesized. These polymers were synthesized by reacting fluoro-terminated poly(arylene ether sulfone) chains with an arylene ether ketone AB2 monomer. The terminal groups of these polymers were capped by tert-butylphenol. The results from NMR and SEC showed that multiple tert-butyl units were successfully introduced onto the polymer chains, suggesting that this synthetic method could be useful for introducing multiple functional groups onto the polymer chain ends in fewer synthetic steps than an analogous method using preformed dendritic end-cappers. It was also demonstrated that multiple sulfonated phenols were attached to the terminal groups of polysulfones by this method. A novel cyclohexyl-containing difunctional monomer was prepared and successfully incorporated into poly(arylene ether sulfone) backbones. These polymers were characterized by NMR, SEC, DSC, TGA, DMA and tensile tests and compared to terephthaloyl analogs. Tensile tests and DMA showed the cyclohexyl units impart a higher magnitude of secondary relaxation than the terephthaloyl units while maintaining high modulus, suggesting that these polymers may have higher impact strength than the ones with no cyclohexyl units. / Ph. D.

Proton exchange membrane fuel cells (PEMFCs) have been extensively studied as clean, sustainable and efficient power sources for electric vehicles, and portable and residential power sources. As one of the key components in PEMFC system, proton exchange membranes (PEMs) act as the electrolyte that transfers protons from the anode to the cathode. The state-of-art commercial PEM materials are typically based on perfluorinated sulfonic acid containing ionomers (PFSAs), represented by DuPont's Nafion®. Despite their good chemical stability and proton conductivity at high relative humidity (RH) and low temperature, several major drawbacks have been observed on PFSAs, such as high cost, high fuel permeability, insufficient thermo-mechanical properties above 80°C, and low proton conductivity at low RH levels. Therefore the challenge lies in developing alternative PEMs which feature associated ionic domains at low hydration levels. Nanophase separated hydrophilic-hydrophobic block copolymer ionomers are believed to be desirable for this purpose Three series of hydrophobic/hydrophillic, partially fluorinated/sulfonated multiblock copolymers were synthesized and characterized in this thesis. The hydrophilic blocks were based upon the nucleophilic step polymerization of 3, 3′-disulfonated, 4, 4′-dichlorodiphenyl sulfone (SDCDPS) with an excess 4, 4′-biphenol (BP) to afford phenoxide endgroups. The partially fluorinated hydrophobic blocks were largely based on 4, 4′-hexafluoroisopropylidenediphenol (6F-BPA) and various difluoro monomers (excess). These copolymers were obtained through moderate temperature (~130-150°C) coupling reactions, which minimize the ether-ether interchanges between hydrophobic and hydrophilic telechelic oligomers via a nucleophilic aromatic substitution mechanism. The copolymers were obtained in high molecular weights and were solvent cast into tough membranes, which had nanophase separated hydrophilic and hydrophobic regions. The performance and structure-property relationships of these materials were studied and compared to random copolymer systems. NMR results supported that the multiblock sequence had been achieved. They displayed superior proton conductivity, due to ionic, proton conducting channels formed through the self-assembly of the sulfonated blocks. The nano-phase separated morphologies of the copolymer membranes were studied and confirmed by transmission electron microscopy (TEM) and small angle X-ray scattering (SAXS). Through control of a variety of parameters, including ion exchange capacity and sequence lengths, performances as high, or even higher than those of the state-of-the-art PEM, Nafion®, were achieved. Another series of semi-crystalline hydrophobic poly(ether ether ketone)-hydrophilic sulfonated poly(arylene ether sulfone) (PEEK-BPSH100) multiblock copolymers was first synthesized and characterized. However due to their semi-crystalline structure, PEEK blocks are insoluble in most organic solvents at relatively low reaction temperatures, which prevents the coupling reaction between PEEK and BPS100. In order to facilitate the synthesis and processing, removable bulky ketimine was introduced to synthesize amorphous pre-oligomers poly(ether ether ketimine) (PEEKt). The synthetic procedure first involves the synthesis of hydrophobic poly(ether ether ketimine)-hydrophilic sulfonated poly(arylene ether sulfone) (PEEKt-BPS100) multiblock pre-copolymers via coupling reactions between phenoxide terminated hydrophilic BPS100 and fluorine terminated hydrophobic PEEKt blocks. The membranes cast from PEEKt-BPS100 were boiled in 0.5M sulfuric acid water solution to hydrolyze the amorphous PEEKt blocks to semi-crystalline PEEK blocks and acidify BPS100 blocks to BPSH100 blocks simultaneously. FT-IR spectra clearly showed the successful hydrolysis and acidification. The proton conductivity, water uptake and other membrane properties of the acidified semi-crystalline PEEK-BPSH100 membranes were then evaluated and compared with those of the state-of-the-art PEM, Nafion®. / Ph. D.

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The results described in this dissertation have demonstrated several alternative proton exchange membranes (PEM) for hydrogen-air and direct methanol fuel cells (DMFC) that perform as well or better than the state of the art Nafion perfluorosulfonic acid membrane. Direct aromatic nucleophilic substitution polycondensations of disodium 3,3′ S-disulfonate-4,4′ S-difluorodiphenylsulfone (SDFDPS), 4,4′ S-difluorodiphenylsulfone (DFDPS) (or their chlorinated analogs, SDCDPS, DCDPS) and 4,4′ S-thiobisbenzenethiol (TBBT) in the presence of potassium carbonate were investigated. Electrophilic aromatic substitution was employed to synthesize the SDFDPS or SDCDPS comonomers in high yields and purity. High molecular weight disulfonated poly(arylene thioether sulfone) (PATS) copolymers were easily obtained using the SDFDPS monomers, but in general, slower rates and a lower molecular weight copolymer was obtained using the analogous chlorinated monomers. Tough and ductile membranes were solution cast from N,N-dimethylacetamide for both series of copolymers. The degrees of disulfonation (20-50%, PATS 20-50) were controlled by varying the ratio of disulfonated to unsulfonated comonomers. Composite membranes were prepared by homogeneous solution blending the copolymers with phosphotungstic acid (PTA) in dimethylacetamide (DMAc). The composite PATS membranes exhibited moderate PTA molecule water extraction after acidification treatments performed at either room or boiling temperatures. The membranes containing HPA showed improved conductivity at high temperatures (120 °C) and low relative humidities when compared to the pure copolymers. Molecular weight of the copolymers plays a critical role in the overall copolymer physical behavior. It is well known that molecular weight has an enormous impact on practically all of the physical properties of polymeric systems. This dissertation discusses the influence of molecular weight on the characteristics of a specific family of PEM PATS copolymers. This study elucidated that the lower molecular weight materials did indeed behave differently than the higher molecular weight copolymers. Specifically, the water uptake and permeability to methanol decreased with increasing molecular weight. Furthermore, the fully hydrated mechanical properties also improved with molecular weight. The synthesis and fabrication of 45 mole percent disulfonated poly(arylene ether phenyl phosphine oxide diphenyl sulfone) terpolymer-heteropolyacid (HPA) composite membranes and membrane electrode assemblies were chosen for detailed investigation. A series of 45 mole percent disulfonated biphenol-based poly(arylene ether phenyl phosphine oxide diphenyl sulfone) terpolymers (BPSH45-PPO) were also synthesized by nucleophilic aromatic substitution polymerizations. The level of disulfonation was constant at 45 mole percent providing a compromise between high conductivity at low humidity and reasonable mechanical properties in liquid water. The amounts of 4,4′-difluorodiphenyl phenyl phosphine oxide comonomer incorporated into the terpolymer backbone were precisely controlled from 0-50 mole percent relative to the 4,4′-dihalodiphenyl sulfone. Phosphine oxide moieties were employed to enhance the interactions with the PTA relative to the pure copolymer. The composite BPSH45-PPO membranes exhibited lower HPA molecule water extraction after acidification at room and boiling temperatures, which was ascribed to the strong hydrogen and polar interactions between the phosphine oxide moiety and functional groups on the HPA. The membranes containing HPA displayed improved conductivity at high temperatures and low relative humidities when compared to the pure terpolymer samples. The increase of proton conductivity was attributed to the water retention characteristics of the HPA molecules, which allowed enhanced mobility of the protons even at lower humidification levels, providing superior hydrogen-air fuel cell performance. The effect of hexafluoroisopropylidene bisphenol (6FBP) incorporation into 45 mole percent disulfonated poly(arylene ether sulfone) copolymers was investigated. This novel series of directly disulfonated poly(arylene ether sulfone) copolymers with various mole ratios of the 6FBP were synthesized in high molecular weight. The levels of fluorination within the statistically random copolymer architecture were varied from 0-100 mole percent using 6FBP and the correct stoichiometric amount of 4,4′-biphenol. The 6FBP monomer was introduced to decrease the water swelling and improve bonding characteristics with Nafion-bonded electrodes. Indeed, water uptake decreased with increasing incorporation of the 6FBP monomer into the terpolymer. This suggested that the hydrophobic fluorinated material aided in water repulsion of the system. Proton conductivity decreased slightly as the amount of fluorination increased, which was interpreted to be due to the decrease in the ion-exchange capacity. High temperature hydrogen/air fuel cell experiments indicated better Nafion-bonded electrode adhesion for the partially fluorinated materials, as depicted by high temperature (120 °C) and low humidity (50% RH) hydrogen-air fuel cell performance. Investigations into polymeric electromechanical transducers were based on poly(arylene sulfone) ion-exchange membranes bonded between two conductive metal layer electrodes. Imposed deformations and small electric fields allowed similar explorations of both sensing and actuation applications. These copolymers produced larger sensitivities than the benchmark Nafion systems, which was interpreted as being due to their higher hydrated moduli. Methodologies for better defining the morphology of the electrodes were identified to enhance the capacitance and effective interfacial area of the conductive electrodes. The new procedures afforded major improvements to performance and transduction. Transducer actuation at lower frequencies was improved by employing a new direct assembly electrode fabrication technique that suggested a strong correlation between the capacitance and charge motion. / Ph. D.

Sulfonated poly(arylene ether sulfone)s as ion conductive copolymers have numerous potential applications. Membranes cast from these copolymers are desirable due to their good chemical and thermal stability, excellent mechanical strength, satisfactory conductivity, and excellent transport properties of water and ions. These copolymers can be used in a variety of topologies. Structure-property-performance relationships of these membranes as candidates for electrolysis of water for hydrogen production and for purification of water from dissolved ions have been studied. Linear and multiblock sulfonated poly(arylene ether sulfone)s are potential alternative candidates to Nafion membranes for hydrogen gas production via electrolysis of water. In this investigation, these copolymers were prepared from the direct polymerization of di-sulfonated and non-sulfonated comonomers with bisphenol monomers. In systematic investigations, a series of copolymers with modified properties were synthesized and characterized by changing the ratio of the sulfonated/non-sulfonated comonomers in each reaction. These copolymers were investigated in terms of mechanical stability, proton conductivity and H2 gas permeability at a range of temperatures and under fully hydrated conditions. A multiblock copolymer was synthesized and evaluated for its potential as membranes for electrolysis of water and for fuel cell applications. The multiblock copolymer contained some fluorinated repeat units in the hydrophobic blocks, and these were coupled with a fully disulfonated hydrophilic block prepared from 3,3'-disulfonate-4,4'-dichlorodiphenyl sulfone and biphenol. After annealing, the multiblock copolymer showed enhanced proton conductivity and a more ordered morphology in comparison to the random copolymer counterparts. At 90 oC and under fully hydrated conditions, improved proton conductivity and controlled H2 gas permeability was observed. Finally, the performance of the multiblock copolymer, which was measured as the ratio of proton conductivity to H2 gas permeability, was improved when compared to the state-of-the-art membrane, Nafion 212, by a factor of 3. In another systematic study, two series of random copolymers were synthesized and characterized, and then cast into membranes to evaluate for electrolysis of water. One series contained solely hydroquinone as the phenolic monomer, while the second series contained a mixture of resorcinol and hydroquinone as phenolic comonomers. The polymers that contained only the hydroquinone monomer showed exceptionally good mechanical properties due to the para-substituted comonomer in the composition of the polymer. In the resorcinol-hydroquinone series, gas permeability was constrained due to the presence of 25% of the meta-substituted comonomer incorporated into its structure. Low gas permeability and high proton conductivity at elevated temperatures were obtained for both the linear random and multiblock copolymers. Performance of these copolymers was superior to Nafion at elevated temperatures (80-95°C). In order to enhance the durability of these materials in their hydrated states at elevated temperatures, the surfaces of these copolymer films were treated with fluorine gas. In comparison with pristine non-fluorinated membranes, the modified membranes showed decreased water uptake and longer durability in Fenton's reagent. A series of linear and crosslinked copolymers were investigated with respect to their potential for use as membranes for desalination of water by electrodialysis and reverse osmosis. The crosslinked membranes were prepared by reacting controlled molecular weight, disulfonated oligomers that were terminated with meta-aminophenol with an epoxy reagent. The oligomers had systematically varied degrees of disulfonation and either 5000 or 10,000 Da controlled molecular weights. Membrane casting conditions were established to fabricate highly crosslinked systems with greater than 90% gel fractions. At such a high gel fraction, the water uptake of the crosslinked membranes was lower than that of the linear biphenol-based, disulfonated random copolymer with a similar IEC. Among these series of copolymers, it was shown that the crosslinked membranes cast from the oligomers with 50% degree of disulfonation and a molecular weight of 10,000 Da had the lowest salt permeability of 10-8 cm2/sec. For desalination applications, a comonomer was synthesized with one sulfonate substituent on 4,4'-dichlorodiphenyl sulfone. This new monosulfonated comonomer allows for even distribution of the ions on the linear copolymer backbone, and this may be important for controlling ion transport. Mechanical tests were conducted on the membranes while they were submerged in a water bath. The ultimate strength of a fully hydrated copolymer with an IEC of 1.36 meq/g was approximately 60 MPa with an elongation at break of 160%. Moreover, in a monovalent/divalent mixed salt solution, the monosulfonated linear copolymer exhibited a constant Na+ passage of less than 1.0%. / Ph. D.

The results described in this dissertation focus on the synthesis and utilization of several disulfonated poly(arylene ether) random copolymer membranes in fuel cell and reverse osmosis applications. Poly(arylene ether)s were prepared by direct step copolymerization using a third monomer 3,3–-disulfonated 4,4–-dichlorodiphenylsulfone. The membrane properties of a 4,4–-biphenol-based disulfonated poly (arylene ether sulfone) random copolymer (BPS-35), optionally blended with various fluorine containing polymers or unsulfonated biphenol-based poly (arylene ether sulfone)s (Radel R) were investigated for fuel cell applications. Fluorine containing copolymers used included with 2,2–-hexafluoroisopropylidene 4,4–-biphenol based unsulfonated (6F-00) or disulfonated (6FS-35 and 6FS-60) PAES, hexafluoroisopropylidene biphenol based 4,4–-difluoro phenyl phosphine oxide) (6FPPO), and poly(vinylidene fluoride) (Kynar®). Tapping mode atomic force microscopy (TM-AFM) images of the membranes with 10 wt% of fluorinated copolymers showed macroscopic phase separation. Good miscibility between the copolymers at low concentrations was also confirmed by the observation of only one glass transition temperature. Compared to the benchmark Nafion 1135, the 10wt% blends of the fluorinated copolymers afforded a considerable reduction in the methanol permeabilities, which is important for direct methanol fuel cells (DMFC). The best DMFC performance with 0.5 M methanol fuel was illustrated with blends containing 10 wt% 6FS-00. At higher methanol concentrations (up to 2.0 M) BPS-35/6FS-00 (90/10) membranes outperformed both Nafion membranes. Blends of BPS-35 blends with 6FS-35 or Radel R were also used as RO membranes. The highest salt rejections of 97.2 and 98.0% were obtained from BPS35/Radel R (90:10) and BPS-35/6FS-35 (95:5) blends, respectively in the salt form. A systematic study of the preparation of BPS-20 random copolymer skin-core asymmetric membranes by diffusion induced phase separation (DIPS) from various polar aprotic solvent or cosolvent systems is reported. The best aprotic solvents to generate an asymmetric structure were NMP and DMAc whereas tetrahydrofuran (THF)/ formamide (FAm) (80/20 v/v) mixtures proved to be the best co-solvent systems. Acetone was the best non-solvent to prepare asymmetric membranes from both aprotic solvents and co-solvent mixtures. Overall, asymmetric membranes prepared from THF/FAm co-solvent mixtures illustrated the most stable phase separated morphology that was free of macrovoids. However, thicker skins (~5 μM) were formed due to the high volatility of THF. Therefore, ultra-thin skin thin film composites (TFC) based on BPS-20 in diethylene glycol (Di(EG) were prepared. Thermal treatment of these TFC was conducted at 90 °C and the addition of 20 wt% glycerin to the casting formulation helped to prevent pore collapse in the porous Udel polysulfone. A minimum of three coats was required to obtain a dense, smooth, and pinhole free skin layer. The generation of three dimensional (ternary) solubility parameter phase diagrams based on experimental data was formulated and a region of solubility based on the solubility parameters of the aprotic solvents and the different co-solvent systems was established for BPS-20. / Ph. D.