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Step-growth polymerization facilitates the synthesis of a wide range of industrially applicable polymers, such as polyesters and polysulfones. The choice of backbone and end group structure within these polymers drastically impacts the final material properties and processability emphasizing the necessity for thorough understanding of structure-property relationships. Seemingly simple changes, such as exchanging a monomer for its regioisomer, affects the polymers fundamental packing structure triggering a domino effect ultimately influencing the morphological, thermal, mechanical and barrier properties. In conjunction, end groups provide a means by which tunable mechanical properties and application into unique processing methods can be achieved. Synthesizing polyesters with bibenzoate based monomers generates a large range of morphologies. Linear, 4,4' bibenzoate (4,4'BB), is widely considered a mesogenic monomer due to its ability to impart a liquid crystalline (LC) morphology on semi-aromatic polyesters with linear aliphatic spacers. In this body of work, semi-aromatic polyesters using one of 4,4'BB's regioisomers, either 3,4'BB or 3,3'BB, largely resulted in amorphous or semi-crystalline polymers depending on the selection of aliphatic diol. Incorporation of the meta isomer (3,4'BB) into traditionally LC polymers, such as poly(diethylene glycol 4,4'-bibenzoate) and poly(butylene 4,4'-bibenzoate), through copolymerization afforded two polymer series with tunable LC properties. The 3,4'BB exhibited selective disruption of crystalline domains over the LC phase generating a number of polymers with LC glass morphologies. The application of 3,4'BB to a fully-aromatic polyester enabled the synthesis of a novel melt-processable homopolyester with high thermal stability, poly(p-phenylene 3,4' bibenzoate). This structure afforded a nematic LC morphology which revealed beneficial shear-thinning properties similar to industrial standards. The unique LC morphology of this homopolyester inspired further characterization of the range of achievable properties using the basic structure, poly(phenylene bibenzoate), with all the possible regioisomers. This study afforded six polymers systematically varied in chain linearity from a completely meta to a completely para backbone configuration. A range of morphologies were achieved from high Tg amorphous polymers for the meta configurations to semi-crystalline or LC in the polymers with greater linearity. End group functionalization generates influence on polymer properties while limiting the impact on beneficial properties achieved through the backbone structure and packing. Post-polymerization reactions or the addition of a monofunctional endcapper to the polymerization both achieve end group control. In this dissertation, the addition of a monofunctional diester with a sulfonate moiety to a semi-aromatic LC polyester synthesis resulted in a telechelic ionomer. The non-covalent interaction of the ionic groups will hopefully improve the compression and transverse mechanical properties of the LCP. In contrast, post-polymerization functionalization incorporated acrylate groups onto the ends of a basic polysulfones. These reactive groups provided a handle for photo-curing which enabled the 3D printing of the polysulfones using vat photopolymerization. / Doctor of Philosophy / The research within this dissertation encompasses the design of new plastics for consumer and high-performance applications. Since the emergence of synthetic plastics in the 1920’s, these materials have become a necessity in our everyday life with a range of applications in food packaging, microelectronics, architecture, medical devices, automotive, and aerospace. Benefits over metals and glass primarily result from their light weight and wide range of mechanical properties which allow a range of material properties from soft and flexible plastic grocery bags to tough car parts. Different classes of plastics (polymers) are based primarily on the chemicals used to produce the materials, for example polyesters and polysulfones. The chemical structure of these core materials drastically impacts the final properties of the polymers, which in turn influences their application space. This work focused on how subtle changes to these starting chemical structures allows us to tune the final polymer properties. Within the class of polyesters, a focus was placed on materials known as liquid crystalline (LC) polyesters. A liquid crystalline polymer can achieve a physical state between a solid and a liquid which imparts many beneficial properties on the material processing. Liquid-crystal television displays utilized these properties to provide drastically thinner TV’s with higher resolution. Alternatively, LC polyesters find applications traditionally as high-performance fibers, insulators in microelectronics, and stainless-steel replacements in medical applications. Studying the role of chemical structure on the properties of LC polyester enabled the design of materials which improve upon the current technological standards. These changes enabled the design of LC polyesters with lower processing temperatures and the use of fewer starting materials which will inevitably save energy and money during their production. In the case of polysulfones, changing the chemical structure at the end of the polymer chain facilitated the application of novel processing methods, such as 3D printing. The ability to process using this method reduces the amount of material waste during production and provides an opportunity to design novel parts with intricate structures, inaccessible through traditional means.

The thesis is divided into two parts: (1) microfluidic modeling of blood cell flow in constricted microvasculature and (2) the kinetic study of self-assembly of Au nanorods with different lengths. The passive mechanism of the flow of neutrophils was studied by using poly(dimethyl siloxane) microchannels with circular cross-sections as model blood vessels and agarose microgels as model cells. Their velocity and pressure profiles at various locations inside the microchannel with constrictions were studied as functions of (a) the initial velocity of the microgels, (b) the degree at which the channel-at-large tapered into the constriction, and (c) the size of microgels. Previously, our group proposed that the kinetics of self-assembly of Au nanorods resembles that of the reaction-controlled step-growth polymerization. To investigate factors that affect the reactivity of functional groups, self-assembly experiments were performed for nanorods with different lengths and their kinetics was analyzed.

The thesis is divided into two parts: (1) microfluidic modeling of blood cell flow in constricted microvasculature and (2) the kinetic study of self-assembly of Au nanorods with different lengths. The passive mechanism of the flow of neutrophils was studied by using poly(dimethyl siloxane) microchannels with circular cross-sections as model blood vessels and agarose microgels as model cells. Their velocity and pressure profiles at various locations inside the microchannel with constrictions were studied as functions of (a) the initial velocity of the microgels, (b) the degree at which the channel-at-large tapered into the constriction, and (c) the size of microgels. Previously, our group proposed that the kinetics of self-assembly of Au nanorods resembles that of the reaction-controlled step-growth polymerization. To investigate factors that affect the reactivity of functional groups, self-assembly experiments were performed for nanorods with different lengths and their kinetics was analyzed.

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An A2 + B3 polymerization for the synthesis of hyperbranched polymers was altered using oligomeric precursors in place of either one or both of the monomer pairs to synthesize highly branched macromolecules. Unique topologies that are intermediates between long-chain branched and hyperbranched structures were obtained and the term "highly branched" was used to define these novel architectures. Various types of highly branched polymers, such as polyurethanes, poly(urethane urea)s, poly(ether ester)s, and poly(arylene ether)s were synthesized using the oligomeric A2 + B3 strategy. The molar mass of the oligomeric precursor permitted the control of the molar mass between branch points, which led to interesting macromolecular properties, such as superior mechanical performance to conventional hyperbranched polymers, disrupted crystallinity, improved processibility, and a multitude of functional end groups. Highly branched poly(urethane urea)s and polyurethanes exhibited microphase-separated morphologies as denoted by dynamic mechanical analysis. The similarity in soft segment glass transition behavior and mechanical properties of the branched systems with that of the linear analogues suggested these materials have considerable promise for a variety of applications. When a polycaprolactone triol was utilized as the B3 oligomer for the synthesis of highly branched polyurethane elastomers, the high degree of branching resulted in a completely amorphous soft segment, whereas the linear analogue with equivalent soft segment molar mass retained the crystallinity of polycaprolactone segment. Oligomeric A2 + B3 methodology was further utilized to tailor the degree of branching of poly(ether ester)s that were developed based on slow addition of dilute solution of poly(ethylene glycol) (PEG) (A2) to a dilute solution of 1,3,5-benzenetricarbonyl trichloride (B3) at room temperature in the presence of triethylamine. A revised definition of the degree of branching was proposed to accurately describe the branched poly(ether ester)s and the degree of branching decreased as the molar mass of the PEG diols was increased. Moreover, branched poly(arylene ether)s were prepared via a similar oligomeric A2 + B3 polymerization of phenol endcapped telechelic poly(arylene ether sulfone) oligomers (A2) and tris(4-fluorophenyl) phosphine oxide (B3) in solution. Highly branched poly(ether ester)s were also synthesized in the melt phase using the oligomeric A2 + B3 polymerization strategy. Melt polymerization effectively limited the cyclization reactions, which are common in A2 + B3 polymerizations in solution, and overcame the need for large amounts of polymerization solvent typical of A2 + B3 systems. Finally, a new family of telechelic polyester ionomers was synthesized based on phosphonium bromide salt end groups and branching allowed the incorporation of higher levels of ionic end groups compared to linear analogues. / Ph. D.

The synthesis and characterization of step-growth polymers with novel monomers provided materials with tailored properties for emerging technologies. Specifically, multiphase materials (i.e., microphase separated block copolymers) exploit the synergistic relationship of combining polymers with disparate thermal and mechanical properties. The introduction of intramolecular interactions such as hydrogen and ionic bonding into these polymers further tailored their properties for applications including elastomers, electromechanical transducers, and additive manufacturing (AM). A review of recent literature revealed the material properties required for polymeric materials in electromechanical transducers, which aided in the design of polymers for this application. An isocyanate-, catalyst-, and solvent-free approach facilitated the synthesis of segmented polyureas with tunable thermal and mechanical properties. These materials found use as high dielectric elastomers and water-soluble polymers for extrusion-based AM dependent on the backbone composition. Vat photopolymerization (VP) AM served as a technique to 3D printed novel unsaturated polyester resins (UPR). Incorporating a phosphonium ionic liquid as a reactive diluent replaced styrene and reduced the volatility of commonly used UPRs. VP successfully provided 3D structures from these UPRs that demonstrated limited ionic conductivities. An extensive review of the literature surrounding the structure-property relationships of charged block copolymers with varying architectures helped to inform the synthesis of novel, cationic step-growth polymers. The synthesis of a new phosphonium IL facilitated the synthesis of a segmented polyurethane containing a phosphonium-functionalized soft segment for the first time. This phosphonium polyurethane exhibited ionic conductivities comparable to literature examples of block copolymers used for ionic polymer transducers, which suggests that these materials may serve for this application as well. Carbonyldiimidazole provides a novel route towards synthesizing imidazolium ionenes with unique backbone structures. The coupling of poly(ethylene glycol) dibromides with a bis-carbonylimidazole monomer and a commercial aliphatic dibromide led to the formation of segmented imidazolium ionenes. These polymers exhibited significant atmospheric water uptake as well as water solubility. However, the physical properties of the materials suggested that the synthetic procedure resulted in low molecular weights. Suggested future work provides methods for circumventing this issue and proposes next steps for all the projects discussed herein. / Doctor of Philosophy / Emerging technologies require new polymeric materials with intentionally designed properties. Step-growth polymers such as polyesters, polyurethanes, and polyureas find use in many applications of our everyday lives. Although these materials have served mainly as commodity plastics historically, a reimagining of their syntheses and chemical structures makes them accessible for modern technologies. For example, applying green chemistry principles to the synthesis of polyureas resulted in a less toxic synthetic procedure. Polyureas synthesized through this method exhibited elastic properties comparable to classical polyureas and displayed high dielectric constants, which lend them towards use in dielectric elastomer actuators. This chemistry also allowed for the synthesis of water-soluble polyureas, which served as a material for low temperature extrusion additive manufacturing, colloquially known as 3D printing. Vat photopolymerization describes another type of 3D printing that involves the selective curing of liquid resins with light to form a 3D structure. Employing a reactive ionic liquid monomer with a commercially-relevant unsaturated polyester allowed for a nontoxic method of printing these materials, which also imparted ionic conductivity. Finally, the synthesis of positively charged polyurethanes and ionenes led to the production of ionically conductive materials that may find use in polymeric transducers.

Fluoropolymers have useful properties including high thermal stability, chemical resistance, low dielectric constants, and both hydrophobic and oleophobic character, as compared to non-fluorinated analogues. Meanwhile, Diels-Alder polyphenylenes (DAPPs) are known for thermal stability as well as their rigid structure and glassy physical characteristics, which have led to a variety of film and membrane applications. This dissertation merges these two fields by demonstrating a novel and general synthetic approach to highly fluorinated DAPPs. These polymers are expected to retain the physical characteristics of glassy, non-fluorinated DAPPs while also incorporating the desirable attributes of fluoropolymers. The polymer synthesis described herein is based on the well-established polycondensation of bis(cyclopentadienone) (CPD) monomers and dialkynes. Our first main scientific contribution is a general method for preparing CPDs containing both a fluoroaromatic linker and variable fluoroaromatic head-groups. Our CPD synthesis uses nucleophilic aromatic substitution reactions of cyclopentadienyl anions and perfluoroarenes, as well as a new catalytic method of converting cyclopentadiene methylene (CH₂) groups into the corresponding ketones (C=O) that is the primary dissertation subject of Brian S. Hickory in our laboratory. The overall synthesis is notable for its use of inexpensive starting materials, its efficiency, and its structural versatility. Our second main contribution is the synthesis of novel highly fluorinated Diels-Alder polyphenylenes (DAPPs). Fluorinated DAPPs varied in their molecular weight, in the identity of the lateral fluoroaryl substituent (pentafluoro-phenyl or tetrafluoro-4-pyridyl), and in the structure of the aromatic dialkyne monomer. These polymers are glassy materials with high glass transition temperatures and high thermal stability. Since the polyphenylene structure is intrinsically rigid, the polymers form brittle films even at molecular weights of over 30,000 (M_w). Unlike many fluoropolymers, the fluorinated DAPPs are freely soluble in common organic solvents such as tetrahydrofuran and chloroform. An unknown side reaction competes with the polymer propagation and reduces the highest obtainable molecular weights, which limit the ability to form films. However, a stoichiometric imbalance leads to highly fluorinated polyphenylene oligomers terminated with either alkyne or CPD end groups (M_n = 9000). Because preliminary experiments had shown that the desired Diels-Alder propagation reaction was slower than expected, we also undertook a detailed model study of the reaction conditions needed for Diels-Alder reactions of fluorinated CPDs and aromatic alkynes. These experiments showed that protic polar solvents (e.g., m-cresol) and conventional heating at ca. 150 °C optimize reaction rate while minimizing side-reactions that can contribute to lower molecular weight in corresponding polymerization reactions. / Ph. D.

Octafluorobiphenylene-linked bis(cyclopentadienone) was prepared bearing one perfluoro-4-tolyl and one tert-butyl substituent on the terminal diene rings. Polymerizations with 1,4- and 1,3-diethynylbenzene afforded linear Diels-Alder polyphenylenes (DAPPs) having lateral tert-butyl and perfluoro-4-tolyl substituents. The perfluoro-4-tolyl-substituted DAPPs are thermally stable, glassy solids (Tg ~ 230 deg C) that could not be cast into stable films (Mn ~ 10kDa, DPn ~ 10). New compounds perfluoro(1-phenyl-1-octanone) and perfluoro(1,1-diphenyl-1-octanol) were prepared from pentafluorophenylmagnesium bromide and perfluorooctanoyl chloride by nucleophilic acyl substitution and addition reactions. Diels-Alder reactions of 1,2-bis(nonafluorobiphenyl-4-yl)-4-tert-butylcyclopentadiene (CPD-1) with N-(4-fluorophenyl)maleimide (FMI) were explored as models for cyclopentadiene-maleimide-based Diels-Alder polymerizations. Mixtures of five endo/exo adducts were obtained, dependent upon CPD-1 tautomers present at reaction temperatures. The thermodynamic adduct (B3LYP/6-31G* geometry optimizations) was found to be the exo DA adduct of FMI and 2,3-bis(nonafluorobiphenyl-4-yl)-5-tert-butylcyclopentadiene. Five of the six possible isomers were observed and characterized including two by single-crystal X-ray diffraction. Parallel reactions of FMI and 1,2-bis(pentafluorophenyl)-4-tert-butylcyclopentadiene yielded three crystallographically characterized isomers, and with 1H NMR and 19F NMR spectrometry, including 1-D NOE, allowed five isomeric products to be identified. Diene CPD-1 is reactive toward nucleophiles (such as potassium 4-methylphenoxide) at the 4-positions of the C12F9 groups. Using this reactivity pattern, CPD-1 was polymerized with bis(phenol) A (BPA) and bis(phenol-A-6F) (BPAF) to form linear poly(arylene ethers) (Mn ~35 kDa) containing backbone cyclopentadienes. These polymers are glassy solids (Tg ~ 220 deg C) with good thermal stability (Td ~ 290 deg C), and they form stable, creaseable films cast from chloroform solutions. Treatment with 1.5-5.0% of 1,6-bis(N-maleimido)dodecane in N,N-dimethylacetamide (DMAc) at 165 deg C gave insoluble, solvent-swellable networks confirmed using ATR-FTIR. CPD-1 was also used as a cyclopentadiene-based linking group for chain extension of phenol-terminated methyl-PEEK oligomers (PEEKMOHs) with Mn values of 2, 5, and 10 kDa. These polymers are glassy solids (Tg ~ 156 deg C) with good thermal stability (Td ~ 400 deg C), that form stable, creaseable films from chloroform. Segmented polymers were treated with FMI in NMP, and showed functionalization density of approximately 50% by 19F NMR. Segmented polymers were also cross-linked by reaction of 1,6-bis(N-maleimido)hexane (cyclopentadiene to maleimide functional group ratio of 1:1) in NMP at 140 deg C. / Ph. D.

This thesis focuses on my endeavors to prepare new porous polymeric monoliths that are viable to use as supports in flow-through processes. Polymer monoliths of various porous properties and different chemical properties have been prepared utilizing the thermally induced phase separation (TIPS) phenomenon and step-growth polymerization reactions. The aim has been to find appropriate synthesis routes to produce separation supports with fully controlled chemical, physical and surface properties. This thesis includes preparation of porous monolithic materials from several non-cross-linked commodity polymers and engineering plastics by dissolution/precipitation process (i.e. TIPS). Elevated temperatures, above the upper critical solution temperature (UCST), were used to dissolve the polymers in appropriate solvents that only dissolve the polymers above this critical temperature. After dissolution, the homogeneous and clear polymer-solvent solution is thermally quenched by cooling. A porous material, of three dimensional structure, is then obtained as the temperature crosses the UCST. More than 20 organic solvents were tested to find the most compatible one that can dissolve the polymer above the UCST and precipitate it back when the temperature is lowered. The effect of using a mixture of two solvents or additives (co-porogenic polymer or surfactant) in the polymer dissolution/precipitation process have been studied more in depth for poly(vinylidine difluoride) (PVDF) polymers of two different molecular weight grades. Monolithic materials showing different pore characteristics could be obtained by varying the composition of the PVDF-solvent mixture during the dissolute­ion/precipitation process. Step-growth polymerization (often called polycondensat­ion reaction) combined with sol-gel process with the aid of porogenic polymer and block copolymer surfactant have also been used as a new route of synthesis for production of porous melamine-formaldehyde (MF) monoliths. In general, the meso- and macro-porous support materials, for which the synthesis/preparation is discussed in this thesis, are useful to a wide variety of applications in separation science and heterogeneous reactions (catalysis).