Hierarchical Morphology of Poly(ether ether ketone) Aerogels

The phase diagram for the thermoreversible gelation of poly(ether ether ketone) (PEEK) in 4-chlorophenol (4CP) was constructed over broad temperature and concentration ranges, revealing that PEEK is capable of dissolving and forming gels in both 4CP and dichloroacetic acid (DCA) up to a concentration of 25 wt %. Highly porous aerogels of PEEK were prepared through simple solvent exchange followed by one of two drying methods of solvent removal from the wet gel: freeze-drying or supercritical CO2 fluid extraction (SC-drying). The field-emission scanning electron microscopy analysis showed that gelation of PEEK in 4CP, followed by SC-drying, produced aerogels with well-defined lamellar aggregates as compared to less ordered aggregates formed from DCA. Mechanical properties (in compression) were shown to improve with increasing density, resulting in equivalent compressive moduli at comparable density, regardless of the preparation method (gelation solvent selection, concentration variation, or drying method). Nitrogen adsorption–desorption isotherms indicate that PEEK aerogels are comprised of mesopores (2–50 nm diameter pores) formed from stacked crystalline lamella. PEEK aerogels prepared using SC-drying exhibit higher Brunauer–Emmett–Teller surface areas than freeze-dried aerogels of comparable density. The ultra-small-angle X-ray scattering/small-angle X-ray scattering (SAXS)/wide-angle X-ray scattering analysis revealed a hierarchical morphology of the PEEK aerogels with structural features from PEEK crystallites to agglomerates of stacked lamella that spanned a wide range of length scales. SANS contrast-matching confirmed that the morphological origin of the principle scattering feature in PEEK aerogels is stacked crystalline lamella. Nitrogen sorption measurements of porosity and the specific surface area of the PEEK aerogels were correlated with the SAXS analysis to reveal a remarkably high surface area attributed to the platelet-like, lamellar morphology. Contact angle and contact angle hysteresis (CAH) revealed that low-density PEEK aerogels (ρ < 0.15 g/cm3) have water contact angles above the superhydrophobicity cutoff angle (>150°) and a very low CAH near 1°.