Utilizing a thermally induced phase separation process,
poly(phenylene
sulfide) (PPS) thermoreversible gels are developed using for the first
time a benign solvent, 1,3-diphenylacetone (DPA). The PPS/DPA phase
diagram revealed a solid–liquid phase separation mechanism
often observed with crystallizable polymers in good solvents. Two
different methods of determining the Flory–Huggins interaction
parameter, χ, were utilized to understand the polymer–solvent
interactions that govern the phase behavior. Using an experimental
approach, a melting point depression curve was fit to experimental
PPS/DPA melting point data, revealing an interaction parameter of
χ = 0.41. Using accepted Hansen solubility parameters of PPS
and calculated parameters for DPA via a group contribution method,
the polymer–solvent interaction parameter was estimated to
be χ = 0.49. The reasonable agreement between both methods indicates
good interactions between PPS and DPA and verifies the calculated
solubility parameters for DPA. Upon gelation at temperatures below
225 °C, subsequent solvent evacuation via freeze–drying
yields aerogels with low densities ranging from 0.11 to 0.25 g/cm3 and volumetric porosities ranging from 92.3 to 82.2%. The
physical properties of the PPS aerogels were found to be comparable
to similar aerogels made from poly(ether ether ketone) (PEEK). Ultra-small
to wide-angle X-ray scattering (USAXS/SAXS/WAXS) profiles reveal an
ordered, hierarchical morphology with sharp interfaces, whereby the
microstructure is composed of semicrystalline aggregates of stacked
lamella. Scanning electron microscopy micrographs indicate that the
PPS aerogels are highly porous and that the lamellar stacks take the
form of elongated, interconnected fibrils. Power-law scaling of aerogel
density with compressive modulus suggests a tendency of the interconnected
lamellar aggregates to bend and/or buckle in compression in a manner
similar to strut deformation in open-celled foams. Despite their similar
physical properties, PPS aerogels demonstrated higher moduli than
PEEK aerogels at comparable densities due to their network-like morphology.