This paper describes a totally new method for the formation of high molecular weight aromatic polymers. High molecular weight polyarylethersulfones are produced by nickel catalyzed coupling of aryl dichloride monomers. Metallic zinc is used to drive the polymerization reaction which takes place under relatively mild conditions in the presence of triphenylphosphine and a dipolar aprotic solvent. The versatility of the reaction is demonstrated, as well as the ability to provide a variety of high temperature polymers from readily available and inexpensive monomers. It is possible to use an integrated two‐step process to produce aryl dichlorides from inexpensive aryl chlorides, and then to couple these directly to polymer without need for isolation and purification. This process resulted from a fundamental understanding of the chemistry and the use of statistically designed experiments to identify the important reaction parameters and to optimize the degree of polymerization.

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A high-modulus polymer, polysulfone, was evaluated as a porous bone implant material. The bone ingrowth into canine cortical pellets of sintered polysulfone particles was assessed by microradiography and histology. The shear strength of the porous polysulfone-bone interface was determined by push-out and pull-out tests of cortical and trochanteric implants, respectively. Results indicated that the bone ingrowth into porous polysulfone specimens proceeded in such a fashion as to mimic the normal repair at the site. Mechanical testing of cortical and cancellous implants revealed that the interfacial shear strength of the porous polysulfone-bone composite was similar to that achieved using porous metals.

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