Influence of the solvent removal method on the morphology of polystyrene porous structures prepared via thermally induced phase separation

Thermally induced phase separation (TIPS) allows preparation of nano and micro-porous structured materials for various applications. The literature thoroughly examines the impact of initial polymer solution concentration and cooling rate on the products morphology. On the contrary, the influence of the solvent removal methods was so far researched scarcely. Hence, we compare both qualitatively and quantitatively the effects of the solvent removal method on pore size distribution, structure, porosity, and thermal conductivity. Our study was carried out with samples prepared by TIPS from polystyrene/cyclohexane solutions employing either extraction agent or lyophilization at different solvent removal temperatures. Materials exhibited interconnected pore structure, implying good sound insulation properties, and had low thermal conductivity, offering the combination of thermal and sound insulation in one layer of material. Pore sizes after lyophilization were up to two times larger than after solvent removal by an extraction agent. On the other hand, the use of extraction agent led up to 10% porosity decrease with average porosity after lyophilization being above 82%. Our findings demonstrate that the solvent removal method is an important parameter during TIPS and that pros and cons of both methods should be carefully considered to obtain optimal material and TIPS process economy.