This work is concerned with the production of high performance polymer foams via a benign foaming process. The first goal of this project was to develop a process and the conditions necessary to produce a low density (>80% density reduction) foam from poly(arylene ether sulfone) (PAES). Water and supercritical carbon dioxide (scCO2) were used as the blowing agents in a one-step batch foaming process. Both water and scCO2 plasticize the PAES, allowing for precise control on both the foam morphology and the foam density. To optimize the foaming conditions, both thermogravimetric analysis and differential scanning calorimetery (DSC) were used to determine the solubility and the reduced glass transition temperature (Tg) due to plasticization of the polymer. It was determined that 2 hours was sufficient time to saturate the PAES with water and scCO2 when subjected to a temperature of 220 oC and 10.3 MPa of pressure. Under these conditions, a combination of 7.5% of water and scCO2 were able to diffuse into the PAES specimen, correlating to ~60 oC reduction in the Tg of the PAES. The combination of water and scCO2 produced foam with up to an 80% reduction in density. The compressive properties, tensile modulus, and impact strength of the foam were measured. The relative compressive properties were slightly lower than the commercially available structural foam made of poly(methacrylimide). The second objective of the dissertation was to enhance the compressive properties of the PAES foam, without concern for the foam density. Foam was produced over a range of density, by controlling the cell size, in order to optimize the compressive properties. Carbon nanofibers (CNFs) were also added to the PAES matrix prior to foaming to both induce heterogeneous nucleation, which leads to smaller cell size, and to reinforce the cell walls. Dynamic mechanical thermal analysis (DMTA), on saturated CNF-PAES, was used to determine the reduced Tg due to plasticization and establish the temperature for pressure release during foaming. DMTA proved to be more effective than DSC in establishing quantitative results on the reduction in the Tg. The CNF-PAES foam produced had compressive properties up to 1.5 times the compressive properties of the PAES foam. / Ph. D.

Novel proton exchange membranes (PEMs) were investigated that show potential for operating at higher temperatures in both direct methanol (DMFC) and H2/air PEM fuel cells. The need for thermally stable polymers immediately suggests the possibility of heterocyclic polymers bearing appropriate ion conducting sites. Accordingly, monomers and random disulfonated poly(arylene ether) copolymers containing either naphthalimide, benzoxazole or benzimidazole moieties were synthesized via direct copolymerization. The ion exchange capacity (IEC) was varied by simply changing the ratio of disulfonated monomer to nonsulfonated monomer in the copolymerization step. Water uptake and proton conductivity of cast membranes increased with IEC. The water uptake of these heterocyclic copolymers was lower than that of comparable disulfonated poly(arylene ether) systems, which is a desirable improvement for PEMs. Membrane electrode assemblies were prepared and the initial fuel cell performance of the disulfonated polyimide and polybenzoxazole (PBO) copolymers was very promising at 80 C compared to the state-of-the-art PEM (Nafion®); nevertheless these membranes became brittle under operating conditions. Several series of poly(arylene ether)s based on disodium-3,3′-disulfonate-4,4′-dichlorodiphenylsulfone (S-DCDPS) and a benzimidazole-containing bisphenol were synthesized and afforded copolymers with enhanced stability. Selected properties of these membranes were compared to separately prepared miscible blends of disulfonated poly(arylene ether sulfone) copolymers and polybenzimidazole (PBI). Complexation of the sulfonic acid groups with the PBI structure reduced water swelling and proton conductivity. The enhanced proton conductivity of Nafion® membranes has been proposed to be due to the aggregation of the highly acidic side-chain sulfonic acid sites to form ion channels. A series of side-chain sulfonated poly(arylene ether sulfone) copolymers based on methoxyhydroquinone was synthesized in order to investigate this possible advantage and to couple this with the excellent hydrolytic stability of poly(arylene ether)s. The methoxy groups were deprotected to afford reactive phenolic sites and nucleophilic substitution reactions with functional aryl sulfonates were used to prepare simple aryl or highly acidic fluorinated sulfonated copolymers. The proton conductivity and water sorption of the resulting copolymers increased with the ion exchange capacity, but changing the acidity of the sulfonic acid had no apparent effect. / Ph. D.

A designed series of directly copolymerized homo- and disulfonated copolymers containing controlled degrees of pendant sulfonic acid groups have been synthesized via nucleophilic step polymerization. Novel sulfonated poly (arylene ether sulfone) copolymers using 4,4'-bisphenol A, 4,4'-biphenol, hexafluorinated (6F) bisphenol AF, and hydroquinone, respectively, with dichlorodiphenyl sulfone (DCDPS) and 3,3'-disodiumsulfonyl-4,4'-dichlorodiphenylsulfone (SDCDPS) were investigated. Molar ratios of DCDPS and SDCDPS were systematically varied to produce copolymers of controlled compositions, which contained up to 70 mol% of disulfonic acid moiety. The goal is to identify thermally, hydrolytically, and oxidatively stable high molecular weight, film-forming, ductile ion conducting copolymers, which had properties desirable for proton exchange membranes (PEM) in fuel cells. Commercially available bisphenols were selected to produce cost effective alternative PEMs. Partially aliphatic bisphenol A and hexafluorinated (6F) bisphenol AF produced amorphous copolymers with different thermal oxidative and surface properties. Biphenol and hydroquinone was utilized to produce wholly aromatic copolymers. The sulfonated copolymers were prepared in the sodium-salt form and converted to the acid moiety via two different methodologies and subsequently investigated as proton exchange membranes for fuel cells. Hydrophilicity increased with the level of disulfonation, as expected. Moreover, water sorption increased with increasing mole percent incorporation of SDCDPS. The copolymers' water uptake was a function of both bisphenol structure and degree of disulfonation. Furthermore, the acidification procedures were shown to influence the Tg values, water uptake, and conductivity of the copolymers. Atomic force microscopy (AFM) in the tapping mode confirmed that the morphology of the copolymers could be designed to display nanophase separation in the hydrophobic and hydrophilic (sulfonated) regions. Morphology with either co-continuous hydrophobic or hydrophilic domains could be attained for all the sulfonated copolymers. The degree of disulfonation required for continuity of the hydrophilic phase varied with biphenol structure. Proton conductivity values for the sulfonated copolymers, under fully hydrated conditions, were a function of bisphenol and degree of sulfonation. However, at equivalent ion exchange capacities the proton conductivities were comparable. A careful balance of copolymer composition and acidification method was necessary to afford a morphology that produced ductile films, which were also sufficiently proton conductive. The copolymers of optimum design produced values of 0.1 S/cm or higher, which were comparable to the commercial polyperfluorosulfonic acid material Nafion™ control. / Ph. D.

Novel proton exchange (PEM) and reverse osmosis (RO) membranes for application in fuel cell and water purification respectively were developed by synthesis and crosslinking of disulfonated biphenol-based poly (arylene ether sulfone)s (BPS). Crosslinking is a prospective option to reduce the water swelling and improve the dimensional stability of hydrophilic BPS copolymers. Several series of controlled molecular weight, phenoxide-endcapped BPS copolymers were synthesized via direct copolymerization of disulfonated activated aromatic halide monomers. The degree of disulfonation was controlled by varying the molar ratio of sulfonated to non-sulfonated dihalide monomers. The molecular weights of the copolymers were controlled by offsetting the stoichiometry between biphenol and the dihalides. Biphenol was utilized in excess to endcap the copolymers with phenoxide groups, so that the phenoxide groups could be further reacted with a suitable crosslinker. Several crosslinking reagents such as methacrylate, multifunctional epoxy, phthalonitrile and phenylethynyls were investigated. A wide range of crosslinking chemistries i.e. free radical (methacrylate), step growth (epoxy), heterocyclic (phthalonitrile) and acetylenic (phenylethynyl) was explored. The effects of crosslinking on network properties as functions of molecular weight and degree of disulfonation of copolymers, crosslinking time and concentration of crosslinker were studied. The crosslinked membranes were characterized in terms of gel fraction, water uptake, swelling, self-diffusion coefficients of water, proton conductivity, methanol permeability, water permeability and salt rejection. In general, all of the crosslinked membranes had lower water uptake and swelling relative to their uncrosslinked counterparts, and less water uptake and volume swelling were correlated with increasing gel fractions. It was possible to shift the percolation threshold for water absorption of BPS copolymers to a higher ion exchange capacity (IEC) value compared to that of the uncrosslinked copolymers by means of crosslinking. This reduced water uptake increased the dimensional stability of higher IEC materials and extended their application for potential PEM or RO membranes. The reduction in water uptake and swelling also increased the effective proton concentration, resulting in no significant change in proton conductivity of the membranes after crosslinking. The self-diffusion coefficients of water and methanol permeability decreased with crosslinking, indicating restricted water and methanol transport. Therefore an improvement in the selectivity (ratio of proton conductivity to water swelling or methanol permeability) of PEMs for application in either H2/air or direct methanol fuel cells was achieved by crosslinking. The epoxy crosslinked BPS copolymers also had significantly enhanced salt rejection with high water permeability when tested in for RO applications. Reductions in salt permeability with increasing crosslinking density suggested that crosslinking inhibited salt transport through the membrane. In addition to the random copolymers, two series of multiblocks endcapped with either a phenoxide-terminated hydrophilic unit or a hydrophobic unit were synthesized and crosslinked with a multifunctional epoxy. Besides the crosslinking study, the effect of sequence distributions of the hydrophilic and hydrophobic blocks in the multiblock copolymers was also investigated. Similar to randoms, crosslinked multiblocks had lower water uptake and swelling but comparable proton conductivities relative to their uncrosslinked analogues. / Ph. D.

In this dissertation, two approaches were taken to design aqueous dispersible or soluble high performance ion containing polymers to be used as composite system interfacial modifiers and processing aids. In the first approach, thermally stable pyridine containing poly(ary/ene ether)s were designed which could be ionized by protonation in acidic aqueous media. A novel pyridine containing bisphenol monomer, 2,6-(p-hydroxyphenoxy)pyridine, was synthesized and utilized as a monomer for the synthesis of these pyridine moiety containing, high performance polymers containing sulfone, sulfoxide, phosphine oxide, ketimine, and ketone moieties. These pyridine containing poly(arylene ether)s can function as electrostatic stabilizers, but not as the more efficient steric stabilizers. ThE: second approach endeavored to form controlled molecular weight poly(ether-irTlides) via water soluble poly(amic acid) salt precursors. In this approach controlled molecular weight poly(amic acid)s were synthesized, and treated with stoichiometric quantities of tertiary or quaternary ammonium bases to form poly(amic acid) salts. The imidization conditions, and chemistry of the conversion of the poly(amic acid) salts to imide were studied, with the aim of maintaining the targeted molecular weight distribution and properties analogous to a control polyimide. For the above mentioned aqueous dispersion prepregging process, it is required that the matrix resin be in the form of small uniform particles capable of penetrating the interstices of a tight carbon fiber weave. Sub ~lm dimension poly(ether ether ketone) (PEEK) particles useful for aqueous dispersion prepregging were prepared on a large scale by precipitation from high temperature solvent, quantitatively purified, and shown to display properties analogous to the commercial precursor material. In the final chapter of this dissertation, the synthesis and characterization of a polyolefin macromer, and it's incorporation into a polyester is detailed. These macromers, and the graft polymers resulting, have applicability in the area of polymer blend compatibilization. / Ph. D.

Several types of novel proton exchange membranes which could be used for both direct methanol fuel cells (DMFCs) and hydrogen/air fuel cells were investigated in this work. One of the main challenges for DMFC membranes is high methanol crossover. Nafion, the current perfluorosulfonic acid copolymer benchmark membrane for both DMFCs and hydrogen/air fuel cells, shows very high methanol crossover. Directly copolymerized disulfonated poly(arylene ether sulfone)s copolymers doped with zirconium phosphates and phenyl phosphonates were synthesized and showed a significant reduction in methanol permeability. These copolymer/inorganic nanocomposite hybrid membranes show lower water uptake and conductivity than Nafion and neat poly(arylene ether sulfone)s copolymers, but in some cases have similar or even slightly improved DMFC performance due to the lower methanol permeability. These membranes also show advantages for high temperature applications because of the reinforcing effect of the filler, which helps to maintain the modulus of the membrane, allowing the membrane to maintain proton conductivity even above the hydrated glass transition temperature (Tg) of the copolymer. Sulfonated zirconium phenyl phosphonate additives were also synthesized, and membranes incorporating these materials and disulfonated poly(arylene ether sulfone)s showed promising proton conductivity over a wide range of relative humidities. Single-Tg polymer blend membranes were studied, which incorporated disulfonated poly(arylene ether sulfone) with varied amounts of polybenzimidazole. The polybenzimidazole served to decrease the water uptake and methanol permeability of the membranes, resulting in promising DMFC and hydrogen/air fuel cell performance. / Ph. D.

Semicrystalline thermoplastic polyimides based upon bis(4-aminophenoxy)benzene and related "triphenyl ether" diamines were synthesized via the classical two step amic acid route. More specifically, polyimides were derived from para linked 1,4-bis(4-aminophenoxy)benzene, or TPEQ (triphenyl ether diamine- hydroquinone) and its meta isomer 1,3-bis(4-aminophenoxy)benzene, or TPER (triphenyl ether diamine-resorcinol). The reaction of these diamines with rigid or semi-rigid dianhydrides such as pyromellitic dianhydride (PMDA), biphenyl dianhydride (BPDA), and oxydiphthalic anhydride (ODPA) yields very thermally stable semi-crystalline polymers which have excellent resistance to organic liquids. Amorphous polyimides could be derived from hexafluoroisopropylidene-linked diphthalic anhydride (6FDA), but these systems were not extensively investigated. Importantly, molecular weight characterization of the semicrystalline systems at the soluble amic acid stage was successful by employing hydrodynamic volume calibrated, viscosity detector size exclusion chromatography (SEC). The experimental values were found to be within the targeted <M_n> range of 20-30,000 g/mole. Polyimide powders derived from these ether diamines were prepared by solution imidization at 180°C, to afford about 70% imidized structures as judged by dynamic thermal gravimetric analysis (TGA), before crystallization/precipitation occurred. Relatively small particle sizes ranging from 2 to 25 μm in size were generated, which would be appropriate for thermoplastic polymer matrix composites prepared by powder processing. All specimens showed excellent thermooxidative stability, consistent with the aromatic imide structure. The molecular design of the aromatic polyetherimide repeat unit was critical for the successful utilization of these semicrystalline high performance materials. The metba-linked TPER system when combined with the thermally stable s-biphenyl dianhydride (BPDA) produced a melting endotherm, T_m, at about 395°C, which was well within the thermal stability limitations of organic materials, i.e., less than or approximately 450°C. It was also demonstrated to be important to quantitatively endcap both ends of the chains at about 20-30,000 <M_n> with non-reactive phthalimide groups to achieve appropriate melt viscosities and good melt stability. This was done by off-setting the stoichiometry in favor of the diamine, reacting with a calculated amount of phthalic anhydride and imidizing in bulk above the Tg (≈210°C) at 300°C. These considerations allowed for remarkable melt stability in nitrogen at 430°C for at least 45 minutes, and importantly, repeated recrystallizations from the melt to afford tough, ductile semicrystalline films with excellent solvent resistance. If the macromolecular chains were not properly endcapped, it was demonstrated that viscosity increased rapidly at 430°C, suggesting reactions such as transimidization involving terminal amine end groups with in-chain imide segments and/or other side reactions, which quickly inhibited recrystallization, probably by reducing molecular transport processes. In contrast, polyimides based upon the more rigid para-linked TPEQ did not demonstrate melt or flow characteristics below 400°C, and degraded around the T_m at about 470°C! The less thermally stable TPEQ-ODPA based polyimide did melt around 409°C, and lower molecular weight samples, e.g., 10,000 M_n, recrystallized from the melt after short melt times, but cast films were brittle. It was hypothesized that the weak link may be the relatively electron rich arylene ether bond derived from the ODPA dianhydride. Several alkylated derivatives of TPER were synthesized in good yield by the reactions of alkylated resorcinol precursors with p-fluoronitrobenzene to produce dinitro compounds, which were subsequently reduced. These model diamines were then used to synthesize polyimides by the classical two step route. As expected, few of the polyimides derived from BPDA and these diamines displayed melting transitions (T_m), probably because of poor chain packing. However, they could have potential as new thermally stable membrane materials. Several amorphous polyimides prepared from 1,3-bis(p-aminophenoxy)-4-hexylbenzene were soluble in selected common organic solvents and could be cast into flexible films. / Ph. D.

This thesis research focused on the synthesis and characterization of disulfonated poly(arylene ether sulfone) hydrophilic-hydrophobic segmented and multiblock copolymers for application as proton exchange membranes (PEMs) in fuel cells or as reverse osmosis (RO) membranes for water desalination. The first objective was to demonstrate that synthesizing blocky copolymers using a one oligomer, two monomer segmented copolymerization afforded copolymers with similar properties to those which used a previous approach of coupling two preformed oligomers. A 4,4′-biphenol based hydrophilic block of disulfonated poly(arylene ether sulfone) oligomer of controlled number average molecular weight (Mn) with phenoxide reactive end groups was first synthesized and isolated. It was then reacted with a calculated amount of hydrophobic monomers, forming that block in-situ. Copolymer and membrane properties, such as intrinsic viscosity, tensile strength, water uptake, and proton conductivity, were consistent with those of multiblock copolymers synthesized via the oligomer-oligomer approach. The segmented polymerization technique was then used to synthesize a variety of other copolymers for PEM applications. The well known bisphenol phenolphthalein was explored as a comonomer for either the hydrophilic and hydrophobic blocks of the copolymer. Membrane properties were explored as a function of block length for both series of copolymers. Both series showed that as block length increases, proton conductivity increases across the entire range of relative humidity (30-100%), as does, water uptake. This was consistent with earlier research which showed that the water self-diffusion coefficient scaled with block length. Copolymers produced with phenolphthalein had higher tensile strength, but lower ultimate elongation than the 4,4′-biphenol based copolymers. Multiblock copolymers were also synthesized and characterized to assess their feasibility as RO membranes. A new series of multiblock copolymers was synthesized by coupling hydrophilic disulfonated poly(arylene ether sulfone) (BisAS100) oligomer with hydrophobic unsulfonated poly(arylene ether sulfone) (BisAS0) oligomer. Both oligomers were derived using 4,´-isopropylidenediphenol (Bis-A) as the bisphenol. Phenoxide-terminated BisAS100 was end-capped with decafluorobiphenyl and reacted at relatively low temperatures (~ 100 oC) with phenoxide-terminated BisAS0. Basic properties were characterized as a function of block length. The initial membrane characterization suggested these copolymers may be suitable candidates for reverse osmosis applications, and water and salt permeability testing should be conducted to determine desalination properties. The latter measurements are being conducted at the University of Texas, Austin and will be reported separately. / Ph. D.

No description available.

No description available.