Monolithic space-filling porous materials from engineering plastics by thermally induced phase separation

Six different uncompounded engineering and commodity polymers were evaluated for their ability to produce space-filling monolithic entities by thermally induced phase separation (TIPS) from 22 different solvents. Attempts were first made to dissolve the polymers at elevated temperatures, selected below the boiling point of each solvent. Then the solutions of polymers that were homogeneous dissolved underwent a controlled temperature decrease to induce a phase separation as the upper critical solution temperature was passed. Twelve of the solvents gave monolithic entities by this procedure, materials that were characterized with regard to their specific surface area and pore size distribution. These measured parameters were then correlated with their macroporous morphology, assessed by scanning electron microscopy. Monolithic materials with widely different mesoporous properties were obtained with specific surface areas ranging from 169 m(2)/g to structures with essentially nonporous skeletons and distinct mesopore size distribution modes from 6 to 15 nm. The materials furthermore had a wide variation in their macroporous morphologies-among the same polymer processed in different solvents and between different polymers dissolved in the same solvent. TIPS processing therefore appears to be a viable route to prepare space-filling meso- and macroporous support materials for a wide variety of purposes in separation science and heterogeneous chemistry.