Multiphase systems provide an opportunity to develop both novel processing methods and create advanced materials through combining the properties of dissimilar phases in a synergistic manner. In this work, we detail the halogenation of poly(ether ether ketone) (PEEK) through both solution-state and gel-state functionalization methods. The multiphase gel-state chemistry restricts functionalization to the amorphous regions of the semi-crystalline parent homopolymer and generates a copolymer with a blocky microstructure. Solution-state functionalization yields random copolymers which provide matched sets to the blocky analogs for fundamental investigations into the effects of polymer microstructure on material properties. Halogenating PEEK using N-halosuccinimides allows for direct installation of pendant halogens along the polymer backbone with facile control of halogen identity. For both bromination and iodination, blocky halogenation of PEEK provides faster crystallization kinetics, higher glass transition (Tg) and melting temperatures as well as superior crystallizability than random halogenation. When comparing halogen identity, increasing halogen size results in increased Tgs, decreased backbone planarity, and for copolymers with blocky microstructures, an earlier onset of phase separation. Increasing halogen size also results in decreased crystallizability and crystallization kinetics, however, these deleterious effects are mitigated in blocky microstructures due to colocalization of the pristine repeat units. Iodination also results in greater flame resistance than bromination for PEEK-based copolymers, and preserved crystallizability allows for the generation of flame retardant aerogels. Direct halogenation of PEEK in the gel-state also provided a reactive microstructural template for subsequent functionalization. Through the use of copper mediated cross-coupling chemistries, the aryl halide functionalities were leveraged to decorate the polymer backbone with pendant perfluoroalkyl chains. The blocky perfluoro alkyl PEEK demonstrated preserved crystallizability and serves as a candidate for compatibilization of poly(tetrafluoroethylene)-PEEK polymer blends. Superacid-modified PEEK was synthesized through a similar methodology and demonstrated over 50,000% increased hygroscopicity relative to the parent homopolymer, and exhibited preserved crystallizability. Multiphase systems were also designed to additively manufacture reinforced elastomers through vat photopolymerization using a degradable scaffold approach that challenged the current paradigm that the scaffold only serves as a geometrical template in vat photopolymerization. The scaffold crosslinks were cleaved through a reactive extraction process that liberated the glassy photopolymer backbone and resulted in over 200% increased ultimate strain and 50% increased ultimate stress relative to a control that was subjected to a neutral extraction. Lastly, thermoresponsive micellar ligands were synthesized as a multiphase approach to environmental remediation of metal-contaminated aqueous systems. / Doctor of Philosophy / Multiphase systems, such as a mixture of oil and water, are of great interest due to their ability to exhibit a multitude of properties from one material. Minimizing the size of the phases, through a technique called compatibilization, often improves the properties of the material. A common example is salad dressing, where the oil phase is compartmentalized into microscopic particles using surface-active molecules known as surfactants. Surfactants, also known as amphiphiles, partition to the interface between different phases due to the surfactants being comprised of dissimilar molecular constituents. One way to generate polymeric amphiphiles, where a polymer is a large molecule comprised of a molecular chain of repeating units, is through synthesizing block copolymers. Block copolymers have blocks of different constituents that are colocalized through covalent bonds in the polymer backbone and often exhibit phase separated structures, allowing for enhanced transport properties such as is seen in membranes. Using semi-crystalline polymers in membranes allows for enhanced mechanical integrity, as the crystallites act as physical crosslinks, or tie points, similar to the knots in a 3D rope ladder. These molecular knots limit the distance that the linear segments of the rope ladder can stretch, which in membranes leads to reduced swelling and increased mechanical performance. In this work we use semi-crystalline polymers to generate blocky copolymers through the use of halogenation. Halogenation installs halogen moieties as pendant groups on the polymer backbone, which can then by used as a chemical handle for subsequent reactions to further incorporate functionality into the copolymer and achieve desired properties such as proton (hydrogen nuclei) transport in fuel cell membranes. Halogenation also allows for the generation of blocky semi-crystalline copolymers for compatibilizing polymer blends of materials like poly(tetrafluoroethylene) and poly(ether ether ketone). Also in this work, we discuss the additive manufacturing of mechanically reinforced elastomers. An elastomer is another type of crosslinked network, and a mechanically reinforced elastomer can be through of as a 3D rope ladder where some of the linear segments of rope are replaced with steel bars, thus increasing the amount of work required to deform the network. The last multiphase systems discussed are similar to salad dressing, where there is a continuous water phase and a microscopic particle phase. The microscopic particles in this work are amphiphilic block copolymers that change their solubility in water with temperature and also have functionalities that should allow for the binding of metals from water-based systems.

Polysiloxanes represent a unique class of synthetic polymers, employing a completely inorganic backbone structure comprised of repeating –(Si–O)n– 'siloxane' main chain linkages. This results in an assortment of diverse properties exclusive to the siloxane bond that clearly distinguish them from the –(C–C)n– backbone of purely organic polymers. Previous work has elucidated a methodology for fabricating flexible and elastic crosslinked poly(dimethyl siloxane) (PDMS) constructs with high Mc through a simultaneous crosslinking and chain-extension methodology. However, these constructs suffer the poor mechanical properties typical of lower molecular weight crosslinked siloxanes (e.g. modulus, tear strength, and strain at break). Filled PDMS networks represent another important class of elastomers in which fillers, namely silica and siloxane-based fillers, impart improved mechanical properties to otherwise weak PDMS networks. This work demonstrates that proper silicon-based reinforcing agent selection (e.g. siloxane-based MQ copolymer nanoparticles) and incorporation provides a synergistic enhancement to mechanical properties, whilst maintaining a low viscosity liquid composition, at high loading content, without the use of co-solvents or heating. Rheological analysis evaluates the viscosity while photorheology and photocalorimetry measurements evaluate rate and extent of curing of the various MQ-loaded formulations, demonstrating theoretical printability up to 40 wt% MQ copolymer nanoparticle incorporation. Dynamic mechanical analysis (DMA) and tensile testing evaluated thermomechanical and mechanical properties of the cured nanocomposites as a function of MQ loading content, demonstrating a 3-fold increase in ultimate stress at 50 wt% MQ copolymer nanoparticle incorporation. VP AM of the 40 wt% MQ-loaded, photo-active PDMS formulation demonstrates facile amenability of photo-active PDMS formulations with high MQ-loading content to 3D printing processes with promising results. PDMS polyureas represent an important class of elastomers with unique properties derived from the synergy between the nonpolar nature, unusual flexibility, and low glass transition temperature (Tg) afforded by the backbone siloxane linkages (-Si-O)n- of PDMS and the exceptional hydrogen bond ordering and strength evoked by the bidentate hydrogen bonding of urea. The work herein presents an improved melt polycondensation synthetic methodology, which strategically harnesses the spontaneous pyrolytic degradation of urea to afford a series of PDMS polyureas via reactions at high temperatures in the presence of telechelic amine-terminated oligomeric poly(dimethyl siloxane) (PDMS1.6k-NH2) and optional 1,3-bis(3-aminopropyl)tetramethyldisiloxane (BATS) chain extender. This melt polycondensation approach uniquely circumvents the accustomed prerequisite of isocyanate monomer, solvent, and metal catalysts to afford isocyanate-free PDMS polyureas using bio-derived urea with the only reaction byproduct being ammonia, a fundamental raw ingredient for agricultural and industrial products. As professed above, reinforcement of polysiloxane materials is ascertained via the incorporation of reinforcing fillers or nanoparticles (typically fumed silica) or blocky or segmented development of polymer chains eliciting microphase separation, in order to cajole the elongation potential of polysiloxanes. Herein, a facile approach is detailed towards the synergistic fortification of PDMS-based materials through a collaborative effort between both primary methods of polysiloxane reinforcement. A novel one-pot methodology towards the facile, in situ incorporation of siloxane-based MQ copolymer nanoparticles into segmented PDMS polyureas to afford MQ-loaded thermoplastic and thermoplastic elastomer PDMS polyureas is detailed. The isocyanate-free melt polycondensation achieves visible melt dispersibility of MQ copolymer nanoparticles (good optical clarity) and affords segmented PDMS polyureas while in the presence of MQ nanoparticles, up to 40 wt% MQ, avoiding post-polymerization solvent based mixing, the only other reported alternative. Incorporation of MQ copolymer nanoparticles into segmented PDMS polyureas provides significant enhancements to modulus and ultimate stress properties: results resemble traditional filler effects and are contrary to previous studies and works discussed in Chapter 2 implementing MQ copolymer nanoparticles into chemically-crosslinked PDMS networks. In situ MQ-loaded, isocyanate-free, segmented PDMS polyureas remain compression moldable, affording transparent, free-standing films. / Master of Science / Polysiloxanes, also referred to as 'silicones' encompass a unique and important class of polymers harboring an inorganic backbone. Polysiloxanes, especially poly(dimethyl siloxane) (PDMS) the flagship polymer of the family, observe widespread utilization throughout industry and academia thanks to a plethora of desirable properties such as their incredible elongation potential, stability to irradiation, and facile chemical tunability. A major complication with the utilization of polysiloxanes for mechanical purposes is their poor resistance to defect propagation and material failure. As a result polysiloxane materials ubiquitously observe reinforcement in some fashion: reinforcement is achieved either through the physical or chemical incorporation of a reinforcing agent, such as fumed silica, or through the implementation of a chemical functionality that facilitates reinforcement via phase separation and strong associative properties, such as hydrogen bonding. This research tackles polysiloxane reinforcement via both of these strategies. Facile chemical modification permits the construction PDMS polymer chains that incorporate hydrogen bonding motifs, which phase separate to afford hydrogen bond-reinforced phases that instill vast improvements to elastic behavior, mechanical and elongation properties, and upper-use temperature. Novel nanocomposite formulation through the incorporation of MQ nanoparticles (which observe widespread usage in cosmetics) facilitate further routes toward improved mechanical and elongation properties. Furthermore, with growing interest in additive manufacturing strategies, which permit the construction of complex geometries via an additive approach (as opposed to conventional manufacturing processes, which require subtractive approaches and are limited in geometric complexity), great interest lies in the capability to additively manufacture polysiloxane-based materials. This work also illustrates the development of an MQ-reinforced polysiloxane system that is amenable to conventional vat photopolymerization additive manufacturing: chemical modification of PDMS polymer chains permits the installation of UV-activatable crosslinking motifs, allowing solid geometries to be constructed from a liquid precursor formulation.

Yes / Vat photopolymerization has garnered interest from pharmaceutical researchers for the fabrication of personalised medicines, especially for drugs that require high precision dosing or are heat labile. However, the 3D printed structures created thus far have been insoluble, limiting printable dosage forms to sustained-release systems or drug-eluting medical devices which do not require dissolution of the printed matrix. Resins that produce water-soluble structures will enable more versatile drug release profiles and expand potential applications. To achieve this, instead of employing cross-linking chemistry to fabricate matrices, supramolecular chemistry may be used to impart dynamic interaction between polymer chains. In this study, water-soluble drug-loaded printlets (3D printed tablets) are fabricated via digital light processing (DLP) 3DP for the first time. Six formulations with varying ratios of an electrolyte acrylate …