Vijay S. Wadi,
Kishore K. Jena,
Shahrukh Z. Khawaja,
Vengatesan Muthukumarswamy Ranagraj and
Saeed M. Alhassan*
Department of Chemical Engineering, Khalifa University of Science and Technology, P. O. Box 127788, Abu Dhabi, United Arab Emirates. E-mail: saeed.alkhazraji@ku.ac.ae
First published on 5th February 2019
Sulfur-containing polymers prepared via the inverse vulcanization technique have attracted considerable attention due to the feasibility of the method to produce stable polysulfides with up to 50–90 wt% of sulfur and their wide range of applications from Li–S batteries to catalysis, self-healing and optical materials. Despite many applications, the development of new advanced materials using sulfur is still in the initial stage. Herein, we reported the preparation and processing of a porous sulfur foam for low thermal conductivity applications by combining inverse vulcanization and template removal techniques. Initially, water-soluble template-embedded cross-linked polysulfides were prepared and hot-pressed to the required shape and size. Later, pores were generated by dissolving the template in water. The porosity of the foam was altered by varying the particle size of template materials. The effects of the templates on the porosity and morphology were discussed and correlated with thermal conductivity. The sulfur foam with a smaller pore size and high porosity showed significant decrease in the thermal conductivity up to ∼0.032 W m−1 K−1 at 25 °C, which was much lower than that of pristine sulfur (0.205 W m−1 K−1). The present method offers flexibility to modify the foam structure and properties during preparation and processing.
Recently, a porous sulfur foam was recognised as one of the alternatives to remove toxic metals from water and gas streams. The high surface area of the foam enables the maximum absorption of toxic pollutants from water and gas streams.10,21,22 Hasell et al. first reported the preparation of a porous sulfur foam by creating supercritical carbon dioxide (scCO2) in a reaction vessel.23 The foams showed high porosities and surface areas; however, the preparation method involved the risk of applying high temperature and pressure to generate scCO2. Later, this method was simplified by employing the salt template method to obtain a porous structure and was efficiently used to remove mercury from wastewater.21 However, controlling the porosity and morphology and their effects on the structural property of the foams have not been fully explored.
In our previous work, we demonstrated the capturing of elemental mercury (Hg(0)) from the gas phase using a sulfur foam.24 Herein, we reported the preparation and processing of a pore size-controlled sulfur foam via inverse vulcanization and template removal techniques. The porosities of the foams were altered by varying the particle size of the water-soluble template. The effects of porosity on the morphology and surface area of the foam were discussed and correlated to the thermal conductivity at different temperatures (25 °C to 100 °C).
In this method, initially, template-embedded polysulfides were prepared and hot-pressed to the required shape and size and later treated with water to generate a porous structure. The porosity generated in the foam was mainly governed by the particle size and the physical nature of the template. Hence, it was possible to control the morphology of the foams by the selection of the template materials. Thus, water-soluble compounds such as NaCl, Na2CO3, and PS possessing different particle sizes were chosen as templates to vary the porosity. The main advantage of this method is that the polysulfide properties and porosity can be easily altered during the synthesis and the required foam shape can be obtained in the processing step. The digital images of the hot-pressed samples in different shapes are presented in Fig. 2, suggesting the applicability of the method to prepare samples in diverse shapes and sizes. The objects were intact and free standing, indicating the formation of a strong cross-linked polymer.
The structural analysis and cross-linking reaction of the polymer were confirmed by 1H NMR spectroscopy. The stacked 1H NMR spectrum of the DVB monomer and the cross-linked polymer (SD) is presented in Fig. 3a. In the spectrum, the two alkene CH2 protons of DVB appear at 5.40 and 5.90 ppm and the CH proton appears at 6.83 ppm. These peaks disappeared in the spectrum of SD and new complex aliphatic proton peaks appeared between 1.0 and 3.5 ppm, which confirmed the successful reaction of alkene groups with sulfur. The absence of alkene peaks also ensured the complete consumption of the monomers during the cross-linking reaction. The complexity in the aliphatic region could be due to the fact that the bulk reaction of sulfur and DVB leads to complex cross-linked microstructures.
The FTIR spectra of the sulfur foams are shown in Fig. 3b. The carbon–carbon double bond (CC) peak at 1633 cm−1 completely disappeared and the new C–S stretching peak at 648 cm−1 appeared, which further supported the cross-linking reaction. The band appearing at ∼2950 cm−1 was attributed to methylene stretching in CH–CH2 and S–CH2 units. All the samples showed a broad peak near 3300 cm−1, which was assigned to the OH group that appeared due to the presence of a trace amount of water from water treatment.
X-ray diffraction was used to study the change in the crystallization behaviour of sulfur before and after the cross-linking reaction. A representative example of pure sulfur compared with NaSD and NaCl is presented in Fig. 3c. Sulfur is crystalline in nature; it showed sharp peaks (sulfur 2θ = 23°, 27°, 28°, 53° and 56°), which were absent after the cross-linking reaction, suggesting the formation of an amorphous polymer. Pure NaCl showed the characteristic crystalline diffraction peaks, i.e., 2θ = 31°, 46°, 56°, and 66°; these peaks were also observed for the sample before water treatment. However, the peaks completely disappeared after water treatment, which confirmed the removal of salt from the polymer. Similar results were also observed for the samples containing Na2CO3 and PS as templates (Fig. S1†).
The thermal properties of the prepared samples were studied by DSC and TGA. A representative DSC thermogram of the NaSD foam and pure sulfur is presented in Fig. 3d. Pure sulfur showed a sharp melt transition at T = 119 °C, which indicated its highly crystalline nature. However, the melt transition was absent in the foam after the cross-linking reaction, which further supported the conversion of crystalline sulfur to an amorphous polymer; this was also in good agreement with the XRD results. Tg of the foam was observed well above the room temperature, i.e., at 62 °C, which supported the amorphous nature of the polysulfides. The thermal stability of the sulfur and polymer before and after water treatment was studied by TGA (Fig. 4). Pure sulfur showed initial degradation at 190 °C and degraded completely around 290 °C. However, polysulfides started to degrade at 236 °C, which was much higher than that of pure sulfur; this suggested increased thermal stability due to the strong cross-linking structure. The samples before water treatment (NaSD-B) showed 30% weight loss and 70 wt% residue at 600 °C. The weight loss was due to the degradation of the thermally less stable sulfur and the residue was from the combined weight of DVB and NaCl. However, the foam NaSD-A showed 53 wt% sulfur degradation and 47 wt% residue, which suggested the formation of a robust cross-linked polymer. The weight loss and residue were in good agreement with the initial feed ratio of sulfur and DVB, which further supported the complete conversion of monomers to polymer.
The surface morphology of the samples was analysed by scanning electron microscopy. Fig. 5 shows the SEM images of pure sulfur, various water-soluble templates and the corresponding polysulfides. Powdered elemental sulfur showed particles with irregular shapes (Fig. 5a); however, on heating above the melting point, sulfur melted and was rearranged to a highly crystalline structure, as shown in Fig. 5b. During the inverse vulcanization reaction, cross-linking destroyed the crystalline arrangements of sulfur and it turned into a uniform amorphous polymer (Fig. 5c). The templates PS, Na2CO3 and NaCl used to generate porous structures are presented in Fig. 5d, e and f, respectively. The image shows that the PS particles are spherical in shape and have sizes between 20 and 40 μm, whereas the Na2CO3 particles measure around 100–200 μm and the NaCl particles have sizes between 200 and 500 μm. The polysulfides prepared using corresponding templates (Fig. 5g–i) showed homogeneous dispersion and the surface roughness reflected the shape of the template loaded in the sample. These templates were dissolved in water to generate a porous structure. The amount of template removed was calculated and is presented in Table 1. The samples showed approximately 92–96% removal of the templates by water, which suggested that the particles were interconnected in the cross-linked polysulfide matrix.
Sample name | Initial wt. of samplea in grams | Final wt. of the sample after water treatment in grams | Wt. of the template in the sample in grams (theoretically calculated) | Wt. of the template dissolved in water in grams | Wt% of template removed after water treatment |
---|---|---|---|---|---|
a All samples were prepared in the constant weight ratio of template:sulfur:salt = 3:2:2. Templates were removed by soaking all samples overnight in water. | |||||
NaSD | 3.8 | 2.31 | 1.63 | 1.49 | ∼92 |
CNaSD | 3.5 | 2.08 | 1.5 | 1.42 | ∼95 |
PSSD | 2.9 | 1.7 | 1.24 | 1.2 | ∼96 |
Digital images of the hot-pressed NaSD sample before and after water treatment are shown in Fig. 6g and h, respectively. The circular shape of the sample was not altered even after the removal of the template (Fig. 6h), which suggested the formation of a stable and intact foam.
The cross sections and surface morphologies of the foams analysed by SEM are presented in Fig. 6. All the samples displayed highly porous structures and the nature of the pores resembled the type of template used. The NaSD foam prepared using NaCl showed a larger pore size around 250–500 μm, whereas the CNaSD and PSSD foams showed pores in the range of 20–50 μm. A comparison of the template sizes and the pores generated by them after water treatment is shown in Fig. S2,† which confirms that the pore size and porosity can be controlled by templates. Similarly, the cross section images of all the samples also showed pores sizes comparable to the surface, which indicated that the template particles were interconnected, thus leading to the complete removal by water treatment. Thus, the pores obtained were a mixture of open and closed cells. However, the pore size distribution was uneven, which was attributed to the irregular size and shape of the template particles. The presence of only sulfur and carbon peaks in the EDX (Fig. 6e) results also supported the complete removal of the templates. The elemental mappings of the corresponding polymers are presented in Fig. S3.† The total surface area of the sample is determined by its porosity; however, SEM provides only information about the pore structure and size since the pores formed in the samples are micro to macro in size, which also restricts the use of BET to determine the porosity. Thus, a mathematical formula given in eqn (1) was used to determine the % porosity by measuring the densities of the foams.
(1) |
In general, low-density particles are expected to decrease the overall density and increase the porosity of the material. Thus, for comparison, all the samples were prepared with a constant weight ratio of template and reactants (template:sulfur:DVB = 3:2:2). The densities of the templates and the calculated porosities of the corresponding foams are given in Table 2. NaCl particles exhibited less volume due to their high density, which led to an intact foam with the lowest porosity of 40.23%. However, low-density PS particles acquired a larger volume compared to NaCl and decreased the overall density of the foam. The removal of the templates from the polymer led to increase in the porosity and decrease in the overall density (Table 2). Smaller PS particles resulted in a higher pore volume and more surface area and hence, PSSD samples showed lower density with high porosity of 59.09%. The relationship between density and porosity in the foam was plotted, as presented in Fig. 7a, clearly showing that the low-density foam produces high porosity. An increase in the template weight ratio >70 wt% resulted in fragile samples due to the less cross-linking density and the connectivity between sulfur and DVB; thus, the formed samples could easily break into powder. Hence, an optimum amount of template was required to obtain high porosity as well as a stable and intact structure. The amount of cross-linker also plays a major role in controlling the porosity of a foam. The samples with a small amount of cross-linker exhibited maximum porosity, which was primarily because of less cross-linking density and thus less volume shrinkage. Moreover, the samples with more cross-linkers possessed less porosities, which can be attributed to the higher volume shrinkage associated with higher cross-linking density.24 The porosity governs the surface area of the material; smaller pores result in a higher surface area of the sample. Thus, the porosity and surface area of the foam can be controlled by the template material. Thermal conductivity is a measure of heat conducted by the material at a given temperature. Pure sulfur possesses considerable low thermal conductivity (∼0.205 W m−1 K−1)25 and the generation of a porous structure can further decrease its thermal conductivity. The effective thermal conductivity as a function of temperature for pure sulfur and sulfur foams is shown in Fig. 7. Please note that each specimen was tested at four different temperatures. The porous foams showed low thermal conductivity compared to pure sulfur (Fig. 7). The thermal conductivity of the sample mainly depends on the porosity and hence, PSSD with the highest porosity showed the lowest thermal conductivity of 0.032 W m−1 K−1 at 25 °C. The thermal conductivity of the polymer is expected to increase with the temperature, especially near and above the glass transition temperature.26 However, the porous sulfur polymers were not affected much by the temperature and showed slight increase in the thermal conductivity with an increase in temperature up to 100 °C. This suggested that the less mobility of the sulfur chains and the stability of the porous structure were due to a highly cross-linked structure.
Sample name | Density before water treatment at RT in g cm−3 | Density after water treatment at RT in g cm−3 | % porosity |
---|---|---|---|
Sulfur | 1.96 | N/A | N/A |
NaCl | 2.16 | N/A | N/A |
Na2CO3 | 2.25 | N/A | N/A |
PS | 0.80 | N/A | N/A |
NaSD | 1.63 | 0.88 | 40.23 |
CNaSD | 1.52 | 0.76 | 52.13 |
PSSD | 1.03 | 0.53 | 59.09 |
Fig. 7 (a) Relationship between density and porosity of the copolymer. (b) Thermal conductivity of pure sulfur and porous sulfur copolymers at different temperatures. |
A comparison of the thermal conductivity of sulfur foams with those of commonly available insulators is shown in Table 3. Most of the commercial insulators such as polyester, nylon and phenolic foams exhibited higher conductivities than the sulfur foam except for PU foams. Hence, the synthesized material has the potential to be a good thermal insulator.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c8ra09127g |
This journal is © The Royal Society of Chemistry 2019 |