| Summary: | This thesis is concerned with the development of the Ketonex dispersion process in order to reliably and reproducibly produce PEKK dispersions with controlled properties, together with the modification of pre-existing process parameters to achieve a range of particulate PAEK copolymers. Specific emphasis was placed on industrial considerations, pre-commercial scale-up and addressing potential materials applications. Chapter 1 explores well established methods for the production of PAEKs by both nucleophilic and electrophilic routes. General materials properties are described, and structure-property relationships are discussed. Chapter 2 describes in detail the process parameters associated with the Ketonex dispersion process. Parameters are discussed on a laboratory scale and are related to scale-up, industrial and commercial considerations. Chapter 3 evaluates the production of PEKKs with a range of T:I ratios by the dispersion process. The PEKKs are analysed using a range of techniques and are compared to literature data for process evaluation. Chapter 4 discusses the theory behind the action of the benzoic acid dispersant used in the dispersion process, which results in the production of fine particulate PEKK. A hypothesis involving the nucleation of polymerisation by aluminium benzoate is proposed. Chapter 5 demonstrates how the dispersion process can be modified to produce a range of PAEK copolymers. The incorporation of imide and sulfone co-monomers are evaluated in detail, while a selection of alternative monomers undergo preliminary evaluation. Chapter 6 addresses an epoxy toughening application. Amine end-capped PAEKs are produced by the dispersion process by in situ functionalisation. A protected end-capper is devised, its attachment and deprotection confirmed through a model compound approach and is successfully applied to the polymerisation system.
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