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Godshall GF, Rau DA, Williams CB, Moore RB. Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2024; 36:e2307881. [PMID: 38009658 DOI: 10.1002/adma.202307881] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/05/2023] [Revised: 10/30/2023] [Indexed: 11/29/2023]
Abstract
Additive manufacturing (AM) of aerogels increases the achievable geometric complexity, and affords fabrication of hierarchically porous structures. In this work, a custom heated material extrusion (MEX) device prints aerogels of poly(phenylene sulfide) (PPS), an engineering thermoplastic, via in situ thermally induced phase separation (TIPS). First, pre-prepared solid gel inks are dissolved at high temperatures in the heated extruder barrel to form a homogeneous polymer solution. Solutions are then extruded onto a room-temperature substrate, where printed roads maintain their bead shape and rapidly solidify via TIPS, thus enabling layer-wise MEX AM. Printed gels are converted to aerogels via postprocessing solvent exchange and freeze-drying. This work explores the effect of ink composition on printed aerogel morphology and thermomechanical properties. Scanning electron microscopy micrographs reveal complex hierarchical microstructures that are compositionally dependent. Printed aerogels demonstrate tailorable porosities (50.0-74.8%) and densities (0.345-0.684 g cm-3), which align well with cast aerogel analogs. Differential scanning calorimetry thermograms indicate printed aerogels are highly crystalline (≈43%), suggesting that printing does not inhibit the solidification process occurring during TIPS (polymer crystallization). Uniaxial compression testing reveals that compositionally dependent microstructure governs aerogel mechanical behavior, with compressive moduli ranging from 33.0 to 106.5 MPa.
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Affiliation(s)
- Garrett F Godshall
- Department of Chemistry, Macromolecules Innovation Institute, Virginia Tech, Blacksburg, VA, 24061, USA
| | - Daniel A Rau
- Department of Mechanical Engineering, Macromolecules Innovation Institute, Virginia Tech, Blacksburg, VA, 24061, USA
| | - Christopher B Williams
- Department of Mechanical Engineering, Macromolecules Innovation Institute, Virginia Tech, Blacksburg, VA, 24061, USA
| | - Robert B Moore
- Department of Chemistry, Macromolecules Innovation Institute, Virginia Tech, Blacksburg, VA, 24061, USA
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Ahmad T, Rehman LM, Al-Nuaimi R, de Levay JPBB, Thankamony R, Mubashir M, Lai Z. Thermodynamics and kinetic analysis of membrane: Challenges and perspectives. CHEMOSPHERE 2023; 337:139430. [PMID: 37422221 DOI: 10.1016/j.chemosphere.2023.139430] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/19/2023] [Revised: 06/18/2023] [Accepted: 07/04/2023] [Indexed: 07/10/2023]
Abstract
The ultimate structure of the membrane is determined using two important effects: (i) thermodynamic effect and (ii) kinetic effect. Controlling the mechanism of kinetic and thermodynamic processes in phase separation is essential for enhancing membrane performance. However, the relationship between system parameters and the ultimate membrane morphology is still largely empirical. This review focuses on the fundamental ideas behind thermally induced phase separation (TIPS) and nonsolvent-induced phase separation (NIPS) methods, including both kinetic and thermodynamic elements. The thermodynamic approach to understanding phase separation and the effect of different interaction parameters on membrane morphology has been discussed in detail. Furthermore, this review explores the capabilities and limitations of different macroscopic transport models used for the last four decades to explore the phase inversion process. The application of molecular simulations and phase field to understand phase separation has also been briefly examined. Finally, it discusses the thermodynamic approach to understanding phase separation and the consequence of different interaction parameters on membrane morphology, as well as possible directions for artificial intelligence to fill the gaps in the literature. This review aims to provide comprehensive knowledge and motivation for future modeling work for membrane fabrication via new techniques such as nonsolvent-TIPS, complex-TIPS, non-solvent assisted TIPS, combined NIPS-TIPS method, and mixed solvent phase separation.
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Affiliation(s)
- Tausif Ahmad
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia.
| | - Lubna M Rehman
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia
| | - Reham Al-Nuaimi
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia
| | - Jean-Pierre Benjamin Boross de Levay
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia
| | - Roshni Thankamony
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia
| | - Muhammad Mubashir
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia
| | - Zhiping Lai
- Advanced Membranes and Porous Materials Centre, Division of Physical Science and Engineering, King Abdullah University of Science and Technology, Thuwal, Saudi Arabia.
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Li C, Tang Y, Lin H, Zhang C, Liu Z, Yu L, Wang X, Lin Y. Novel multiscale simulations on the membrane formation via hybrid induced phase separation process based on dissipative particle dynamics. Sep Purif Technol 2023. [DOI: 10.1016/j.seppur.2023.123614] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 04/03/2023]
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Ma W, Zhou Z, Ismail N, Tocci E, Figoli A, Khayet M, Matsuura T, Cui Z, Tavajohi N. Membrane formation by thermally induced phase separation: Materials, involved parameters, modeling, current efforts and future directions. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2022.121303] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
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Ismail N, Pan J, Rahmati M, Wang Q, Bouyer D, Khayet M, Cui Z, Tavajohi N. Non-ionic deep eutectic solvents for membrane formation. J Memb Sci 2022. [DOI: 10.1016/j.memsci.2021.120238] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/26/2022]
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Tang Y, Lin Y, Ford DM, Qian X, Cervellere MR, Millett PC, Wang X. A review on models and simulations of membrane formation via phase inversion processes. J Memb Sci 2021. [DOI: 10.1016/j.memsci.2021.119810] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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Tang Y, Lin Y, Ma W, Wang X. A review on microporous polyvinylidene fluoride membranes fabricated via thermally induced phase separation for MF/UF application. J Memb Sci 2021. [DOI: 10.1016/j.memsci.2021.119759] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
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Isothermal Crystallization of iPP in Environment-friendly Diluents: Effect of Binary Diluents and Crystallization Temperature on Crystallization Kinetics. CHINESE JOURNAL OF POLYMER SCIENCE 2019. [DOI: 10.1007/s10118-019-2219-y] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/11/2023]
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9
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Zhang G, Yang T, Yang S, Wang Y. Morphological-evolution pathway during phase separation in polymer solutions with highly asymmetrical miscibility gap. Phys Rev E 2017; 96:032501. [PMID: 29346882 DOI: 10.1103/physreve.96.032501] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/02/2017] [Indexed: 06/07/2023]
Abstract
Microstructural evolution during thermally induced phase separation in a polymer solution with a highly asymmetrical miscibility gap is analyzed using Flory-Huggins thermodynamics and nonlinear Cahn-Hilliard kinetics. Computer simulation results demonstrate that, in contrast to systems with symmetric miscibility gaps, interesting morphological-evolution pathways (MEPs) including cluster-to-percolation and percolation-to-cluster transitions are identified. These MEPs are rationalized according to asynchronous evolution of the two product phases. For a highly asymmetric polymer system, the initial solution composition is also found to play a critical role in determining the MEPs. According to the simulation results a map of MEPs in terms of initial solution composition and aging time of phase separation is established to guide future microstructural design in asymmetrical polymer solutions.
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Affiliation(s)
- Gang Zhang
- Frontier Institute of Science and Technology, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, State Key Laboratory for Mechanical Behavior of Materials, Xi'an Jiaotong University, Xi'an 710049, China
| | - Tao Yang
- Frontier Institute of Science and Technology, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, State Key Laboratory for Mechanical Behavior of Materials, Xi'an Jiaotong University, Xi'an 710049, China
| | - Sen Yang
- Frontier Institute of Science and Technology, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, State Key Laboratory for Mechanical Behavior of Materials, Xi'an Jiaotong University, Xi'an 710049, China
| | - Yunzhi Wang
- Frontier Institute of Science and Technology, MOE Key Laboratory for Nonequilibrium Synthesis and Modulation of Condensed Matter, State Key Laboratory for Mechanical Behavior of Materials, Xi'an Jiaotong University, Xi'an 710049, China
- Department of Materials Science and Engineering, The Ohio State University, Columbus, Ohio 43210, USA
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Wang C, Quan X, Liao M, Li L, Zhou J. Computer Simulations on the Channel Membrane Formation by Nonsolvent Induced Phase Separation. MACROMOL THEOR SIMUL 2017. [DOI: 10.1002/mats.201700027] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Chu Wang
- School of Chemistry and Chemical Engineering; South China University of Technology; Guangzhou 510460 China
| | - Xuebo Quan
- School of Chemistry and Chemical Engineering; South China University of Technology; Guangzhou 510460 China
| | - Mingrui Liao
- School of Chemistry and Chemical Engineering; South China University of Technology; Guangzhou 510460 China
| | - Libo Li
- School of Chemistry and Chemical Engineering; South China University of Technology; Guangzhou 510460 China
| | - Jian Zhou
- School of Chemistry and Chemical Engineering; South China University of Technology; Guangzhou 510460 China
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