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This dissertation is composed of seven chapters, detailing advances within the area of sulfur polymer chemistry and processing, and highlights the relevance of the work to the fields of polymer science, energy storage, and optics that are enabled through the development of novel high sulfur-content copolymers as discussed in the following chapters. The first chapter is a review summarizing both the historical forays into utilization of elemental sulfur in high sulfur-content materials and the current research on the incorporation of sulfur into novel copolymers and composites for high value added applications such as energy production/storage, polymeric optical components, and dynamic/self-healing materials. Although recent efforts by the materials and polymer chemistry communities have afforded innovative sulfur containing materials, many studies fail to take advantage of the low cost and incredible abundance of sulfur by incorporating only minimal quantities into the end products. A fundamental challenge in the preparation of sulfur-containing polymers is simultaneous incorporation of high sulfur-content through facile chemical methods, to truly use the element as a novel feedstock in copolymerizations. Contributing to the challenge are the intrinsic limitations of sulfur (i.e., low miscibility with organic solvents, high crystallinity, and poor processability). The emphasis in chapter 1 is the critical development of utilizing sulfur as both a reagent and solvent in a bulk reaction, termed inverse vulcanization. Through this methodology we can directly prepare materials which retain the advantageous properties of elemental sulfur (i.e., high electrochemical capacity, high refractive index, and liable bond character), obviate the processing challenges, and enable precise control over composition and properties in a facile manner. The second chapter focuses on advancement in colloid synthesis, specifically an example mediated by in-situ reduction of organometallic precursors (ClAu^IPPh₃) by elemental sulfur at high temperatures. In chapter 2, elemental sulfur is employed both as a reactant and novel solvent, generating composite composed of well-defined gold nanoparticles (Au NPs) fully dispersed in a sulfur matrix. While the synthesis of Au NPs in molten sulfur was a novel development the challenge of analyzing the particles directly within the sulfur composite matrix by microscopy techniques required improvement of the composites mechanical properties. To overcome this issue, a one-pot reaction in which the Au NPs were initially synthesized, was vulcanized through an ambient atmosphere-tolerant bulk copolymerization by the addition of a difunctional comonomer (divinylbenzene). The improved composite integrity enabled microtoming and transmission electron microscopy analysis of the particles within the crosslinked reaction matrix. Due to the facile capabilities of directly dissolving the comonomers within the molten sulfur the inverse vulcanization methodology provides a simple route to prepare stable, high sulfur-content copolymers in a single one-pot reaction. The third chapter expands upon the methodology for direct dissolution of difunctional comonomers into molten elemental sulfur to afford chemically stable copolymer. A major challenge associated with the high temperature (i.e., 185 °C) bulk copolymerization reactions between sulfur and vinyl comonomers (i.e., divinylbenzene, DVB) is the high volatility of the organic monomers at elevated temperatures (BP of DVB = 195 °C). To obviate this problem required a novel monomer with an increased boiling point for successful scaling of the inverse vulcanization methodology. The work presented in chapter 3 details the employment of 1,3-diisopropenylbenzene (DIB, BP = 231 °C) to enable larger scale bulk inverse vulcanization reactions, allowing facile control over thermomechanical properties by simple variation in copolymer composition (50–90-wt% S₈, 10–50-wt% DIB). Poly(Sulfur-random-1,3-diisopropenylbenzene) ((poly(S-r-DIB)) copolymers prepared via the inverse vulcanization methodology possess substantially improved processing capabilities compared with elemental sulfur. A facile demonstration of improved processability is the generation of free-standing micropatterned structures using a high sulfur content liquid pre-polymer resin that can be poured into a mold and cured into the desired final form. The highest weight percentage copolymer (i.e., 90-wt% S₈) was also demonstrated to improve cycle lifetimes and capacity retention (823 mAh•g⁻¹ at 100 cycles) of a Lithium-Sulfur (Li-S) cell when the copolymer was utilized as the active material instead of elemental sulfur. Chapter four focuses on the optimization of Li-S cell performance as a function of copolymer composition and provides a more thorough understanding of the means by which copolymer active material improves battery performance. A substantial challenge associated with Li-S cells is the fast capacity fade and short cycle lifetimes that result from loss of the active material (i.e., sulfur) during normal cycling processes. The field has generally addressed these issues by encapsulation of the sulfur in a protective shell (e.g., polymeric, carbonaceous, or metal oxide in nature) in an attempt to sequester the active material. However, encapsulation of sulfur is non-trivial and leads to low loadings of sulfur, resulting in a low energy density within the final cell. To address the challenges associated with maintaining high capacity and long cycle lifetimes while employing an active material which is low cost, generated in a facile manner, and has a high sulfur content required a novel approach. In the work presented in chapter 4 we prepared high sulfur content copolymers via the inverse vulcanization methodology, which meet all the requirements necessary of an active material, and investigated the performance of Li-S batteries as a function of the copolymer composition. A survey of several poly(S-r-DIB) copolymer compositions were prepared with DIB compositions ranging from 1-50-wt% DIB (i.e., 50-99 wt% sulfur) and screened to determine optimal compositions for optimal Li-S battery performance. From this analysis it was determined that copolymers with 10-wt% DIB (90-wt% S₈) were optimal for producing Li-S batteries with high capacity and long cycle lifetimes. 10-wt% DIB copolymers batteries ultimately achieved long cyclic lifetimes and maintained high capacity (>600 mAh/g at 500 cycles). Chapter five details the optimization of conditions necessary to generate large scale (>100 g) inversely vulcanized sulfur copolymers and their application towards Li-S batteries. As previously stated a significant challenge in the Li-S battery field is the production of a Li-S active material with improved performance that is low cost, synthesized in a facile manner, and possesses high sulfur content. To date poly(S-r-DIB) copolymers prepared via the inverse vulcanization methodology afford some of the longest cycle lifetimes and highest capacity retention for polymeric active materials. However, initial inverse vulcanization reactions investigated for preparing active materials were performed on 10 gram scales. The goal of the work presented in chapter 5 was to prepare materials on a scale applicable to fabrication of several prismatic Li-S cells, each of which requires several grams of active material. However, scaling up of the reaction to a kilogram and utilizing the traditional inverse vulcanization conditions (i.e., 185 °C) results in catastrophic degradation as a consequence of the Trommsdorf effect. To address this challenge required decreasing the radical concentration within the bulk copolymerization, which necessitated performing the kilogram scale inverse vulcanization reactions at lower temperatures (i.e., 130 °C) over a longer reaction period. Decreasing the temperature generates materials that are nearly identical in thermomechanical properties to smaller scale samples and the battery performance is likewise comparable (>600 mAh/g at 500 cycles). The key advantage of performing the inverse vulcanization reaction at lower temperatures is that additional monomers, with lower boiling points or degradation issues, can be utilized and the increased gelation time, enables facile incorporation of additives (e.g., carbon black or nanoparticles) into the reaction. Chapter six focuses on the development of poly(S-r-DIB) copolymers as novel mid-infrared (mid-IR) transmitting materials and the analysis of the optical properties as a function of copolymer composition. A challenge in the optical science community is the limited number of materials applicable to the development of innovative optical components capable of functioning in the mid and far-IR regions. Semi-conductor and chalcogenide glasses have been widely applied as device components in infrared optics due to their high refractive indices (n ~2.0–4.0) and high transparency in the infrared region (1–10 μm). However, such materials are also expensive, difficult to fabricate, and toxic in comparison to organic polymers. On the other hand organic polymers are easily processed, low cost, and generated from easily accessible raw materials. Unfortunately, polymeric materials generally have low refractive indices (n |
