Hierarchical Morphology of Poly(ether ether ketone) Aerogels

High Modulus, Strut-like poly(ether ether ketone) Aerogels Produced from a Benign Solvent

Poly(ether ether ketone) (PEEK) was found to form gels in the benign solvent 1,3-diphenylacetone (DPA). Gelation of PEEK in DPA was found to form an interconnected, strut-like morphology composed of polymer axialites. To our knowledge, this is the first report of a strut-like morphology for PEEK aerogels. PEEK/DPA gels were prepared by first dissolving PEEK in DPA at 320 °C. Upon cooling to 50 °C, PEEK crystallizes and forms a gel in DPA. The PEEK/DPA phase diagram indicated that phase separation occurs by solid-liquid phase separation, implying that DPA is a good solvent for PEEK. The Flory-Huggins interaction parameter, calculated as χ12 = 0.093 for the PEEK/DPA system, confirmed that DPA is a good solvent for PEEK. PEEK aerogels were prepared by solvent exchanging DPA to water then freeze-drying. PEEK aerogels were found to have densities between 0.09 and 0.25 g/cm3, porosities between 80 and 93%, and surface areas between 200 and 225 m2/g, depending on the initial gel concentration. Using nitrogen adsorption analyses, PEEK aerogels were found to be mesoporous adsorbents, with mesopore sizes of about 8 nm, which formed between stacks of platelike crystalline lamellae. Scanning electron microscopy and X-ray scattering were utilized to elucidate the hierarchical structure of the PEEK aerogels. Morphological analysis found that the PEEK/DPA gels were composed of a highly nucleated network of PEEK axialites (i.e., aggregates of stacked crystalline lamellae). The highly connected axialite network imparted robust mechanical properties on PEEK aerogels, which were found to densify less upon freeze-drying than globular PEEK aerogel counterparts gelled from dichloroacetic acid (DCA) or 4-chlorphenol (4CP). PEEK aerogels formed from DPA were also found to have a modulus-density scaling that was far more efficient in supporting loads than the poorly connected aerogels formed from PEEK/DCA or PEEK/4CP solutions. The strut-like morphology in these new PEEK aerogels also significantly improved the modulus to a degree that is comparable to high-performance crosslinked aerogels based on polyimide and polyurea of comparable densities.

Poly(vinylidene fluoride) Aerogels with α, β, and γ Crystalline Forms: Correlating Physicochemical Properties with Polymorphic Structures

Strategic customization of crystalline forms of poly(vinylidene fluoride) (PVDF) aerogels is of great importance for a variety of applications, from energy harvesters to thermal and acoustic insulation. Here, we report sustainable strategies to prepare crystalline pure α, β, and γ forms of PVDF aerogels from their respective gels using a solvent exchange strategy with green solvents, followed by a freeze-drying technique. The crucial aspect of this process was the meticulous choice of appropriate solvents to enable the formation of thermoreversible gels of PVDF by crystallization-induced gelation. Depending on the polymer-solvent interactions, the chain conformation of PVDF can be modulated to obtain gels and aerogels with specific crystalline structures. The crystalline pure α-form and piezoelectric β-form aerogels were readily obtained by using cyclohexanone and γ-butyrolactone as gelation solvents. On the other hand, the γ-form aerogel was obtained using a binary solvent system consisting of dimethylacetamide and water. These aerogels with distinct crystalline structures exhibit different morphologies, mechanical properties, hydrophobicities, acoustic properties, and electrical properties. Measurement of thermal conductivity for these aerogels showed exceptionally low thermal conductivity values of ∼0.040 ± 0.003 W m-1 K-1 irrespective of their crystal structures. Our results showcase the fabrication approaches that enable PVDF aerogels with varied physicochemical properties for multifunctional applications.

Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation

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.

X-ray scattering as an effective tool for characterizing liquid metal composite morphology

Quantitative analysis of particle size and size distribution is crucial in establishing structure-property relationships of composite materials. An emerging soft composite architecture involves dispersing droplets of liquid metal throughout an elastomer, enabling synergistic properties of metals and soft polymers. The structure of these materials is typically characterized through real-space microscopy and image analysis; however, these techniques rely on magnified images that may not represent the global-averaged size and distribution of the droplets. In this study, we utilize ultra-small angle X-ray scattering (USAXS) as a reciprocal-space characterization technique that yields global-averaged dimensions of eutectic gallium indium (EGaIn) alloy soft composites. The Unified fit and Monte Carlo scattering methods are applied to determine the particle size and size distributions of the liquid metal droplets in the composites and are shown to be in excellent agreement with results from real-space image analysis. Additionally, all methods indicate that the droplets are getting larger as they are introduced into composites, suggesting that the droplets are agglomerating or possibly coalescing during dispersion. This work demonstrates the viability of X-ray scattering to elucidate structural information about liquid metal droplets for material development for applications in soft robotics, soft electronics, and multifunctional materials.

Morphology and properties of foamed high crystallinity PEEK prepared by high temperature thermally induced phase separation

Polyetheretherketone (PEEK) is a high‐performance semi‐crystalline thermoplastic polymer with outstanding mechanical properties, high thermal stability, resistance to most common solvents, and good biocompatibility. A high temperature thermally induced phase separation technique was used to produce PEEK foams with controlled foam density from PEEK in 4‐phenylphenol (4PPH) solutions. Physical and mechanical properties, foam and bulk density, surface area, and pore morphology of foamed PEEK were characterized and the role of PEEK concentration and cooling rate was investigated. Porous PEEK with densities ranging from 110 to 360 kg/m³ with elastic moduli and crush strength ranging from 13 to 125 MPa and 0.8 to 7 MPa, respectively, was produced.

Hierarchically Architected Polyvinylidene Fluoride Piezoelectric Foam for Boosted Mechanical Energy Harvesting and Self-Powered Sensor

With the rapid development of wearable electronics, piezoelectric materials have received great attention owing to their potential solution to the portable power source. To enhance the output capability and broaden the application, it is highly desired for the design of piezoelectric materials with a three-dimensional and porous structure to facilitate strain accumulation. Herein, enlightened by hierarchical structures in nature, a hierarchically nested network was constructed in polyvinylidene fluoride (PVDF) foam via solid-state shear milling and salt-leaching technology. The as-prepared foam exhibited two hierarchical levels of pores with diameters of 20∼50 μm and 0.3∼4 μm, by which the porosity and flexibility were significantly enhanced, while the highest piezoelectric output reached 11.84 V and 217.78 nA. As a proof-of-concept, the PVDF piezoelectric foam can also be used to monitor human movement toward the different magnitude of strain and frequency, and simultaneously collect energy in a multidimensional stress field for energy harvesting. This work provides a simple and convenient design idea for the preparation of energy harvesters, which have great application potential as a mechanical energy harvester or self-powered sensor in wearable electronic devices.

False Morphology of Aerogels Caused by Gold Coating for SEM Imaging

The imaging of non-conducting materials by scanning electron microscopy (SEM) is most often performed after depositing few nanometers thick conductive layers on the samples. It is shown in this work, that even a 5 nm thick sputtered gold layer can dramatically alter the morphology and the surface structure of many different types of aerogels. Silica, polyimide, polyamide, calcium-alginate and cellulose aerogels were imaged in their pristine forms and after gold sputtering utilizing low voltage scanning electron microscopy (LVSEM) in order to reduce charging effects. The morphological features seen in the SEM images of the pristine samples are in excellent agreement with the structural parameters of the aerogels measured by nitrogen adsorption-desorption porosimetry. In contrast, the morphologies of the sputter coated samples are significantly distorted and feature nanostructured gold. These findings point out that extra care should be taken in order to ensure that gold sputtering does not cause morphological artifacts. Otherwise, the application of low voltage scanning electron microscopy even yields high resolution images of pristine non-conducting aerogels.

Mechanism of Hydration and Hydration Induced Structural Changes of Calcium Alginate Aerogel

The most relevant properties of polysaccharide aerogels in practical applications are determined by their microstructures. Hydration has a dominant role in altering the microstructures of these hydrophilic porous materials. To understand the hydration induced structural changes of monolithic Ca-alginate aerogel, produced by drying fully cross-linked gels with supercritical CO₂, the aerogel was gradually hydrated and characterized at different states of hydration by small-angle neutron scattering (SANS), liquid-state nuclear magnetic resonance (NMR) spectroscopy, and magic angle spinning (MAS) NMR spectroscopy. First, the incorporation of structural water and the formation of an extensive hydration sphere mobilize the Ca-alginate macromolecules and induce the rearrangement of the dry-state tertiary and quaternary structures. The primary fibrils of the original aerogel backbone form hydrated fibers and fascicles, resulting in the significant increase of pore size, the smoothing of the nanostructured surface, and the increase of the fractal dimension of the matrix. Because of the formation of these new superstructures in the hydrated backbone, the stiffness and the compressive strength of the aerogel significantly increase compared to its dry-state properties. Further elevation of the water content of the aerogel results in a critical hydration state. The Ca-alginate fibers of the backbone disintegrate into well-hydrated chains, which eventually form a quasi-homogeneous hydrogel-like network. Consequently, the porous structure collapses and the well-defined solid backbone ceases to exist. Even in this hydrogel-like state, the macroscopic integrity of the Ca-alginate monolith is intact. The postulated mechanism accounts for the modification of the macroscopic properties of Ca-alginate aerogel in relation to both humid and aqueous environments.

High-Performance Polymer Foams by Thermally Induced Phase Separation

Macroporous, low-density polyetheretherketone, polyetherketoneketone, and polyetherimide foams are produced using a high-temperature, thermally induced phase separation method. A high-boiling-point solvent, which is suitable to dissolve at least 20 wt% of these high-performance polymers at temperatures above 250 °C, is identified. The foam morphology is controlled by the cooling procedure. The resulting polymer foams have porosities close to 80% with surface areas up to 140 m² g^-1 and elastic moduli up to 97 MPa.