POLYMERIC MATERIALS

• US 20090131582A1
• Filed: 06/13/2007
• Published: 05/21/2009
• Est. Priority Date: 06/14/2006
• Status: Abandoned Application

• Current Assignee: Victrex Manufacturing Limited (Victrex PLC)
• Original Assignee: Victrex Manufacturing Limited (Victrex PLC)
• Inventors: Wilson, Brian, Grasmeder, John Russell, Percy, Michael John, Grant, Simon Jonathon
• Application Number:
  US12/304,864
• Publication Number:
  US 20090131582A1
• Time in Patent Office: Days
• US Class Current: 524/592
• CPC Class Codes: C08G 65/4012 Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
• CPC Class Codes: C08L 71/00 Compositions of polyethers obtained by reactions forming an ether link in the main chain of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 71/10 from phenols

Abstract

Polyaryletherketones and a method for producing the same are described wherein, for a given melt viscosity, the melt flow index is higher than expected. Such polymers may be used in situations where relative high flow is desirable.

Claims

1. A polymeric material having a repeat unit of formula

where p represents 0 or 1, said polymeric material having a melt viscosity (MV) measured in kNsm⁻

2 and a Melt Flow Index (MFI), wherein;

(a) when p represents 1, the actual log₁₀ MFI of said polymeric material is greater than the Expected Value for the log₁₀ MFI calculated using the formula;

Expected Value (EV)=−

3.2218x+2.3327 wherein x represents the MV in kNsm<sup>−

2</sup> of said polymeric material;

or

(b) when p represents 0, the actual log₁₀ MFI of said polymeric material is greater than the Expected Value for the log₁₀ MFI calculated using the formula;

Expected Value (EV)=−

2.539y+2.4299 wherein y represents the MV in kNsm<sup>−

2</sup> of said polymeric material.

2. A polymeric material according to claim 1, wherein said polymeric material consists essentially of a repeat unit of formula X where p=1 or where p=0.

3. A polymeric material according to claim 2, wherein:

when p represents 1, the actual log₁₀ MFI of said polymeric material is greater than the Expected Value for the log₁₀ MFI calculated using the formula;

Expected Value (EV)=m₁x+2.33 where x represents the MV in kNsm<sup>−

2</sup> of said polymeric material and m₁ is greater than −

3.00;

or

when p represents 0, the actual log₁₀ MFI of said polymeric material is greater than the Expected Value for the log₁₀ MFI calculated using the formula;

Expected Value (EV)=m₂y+2.43 where y represents the MV in kNsm<sup>−

2</sup> of said polymeric material and m₂ is greater than −

2.5.

4. A polymeric material according to claim 3, wherein m₁ is greater than −

2.8.

5. A polymeric material according to claim 4, wherein m₂ is greater than −

2.45.

6. A polymeric material according to claim 5, wherein m₁ is greater than −

2.45.

7. A polymeric material according to claim 6, wherein m₂ is greater than −

2.35.

8. A polymeric material according to claim 7, wherein the MV of said polymeric material is at least 0.06 kNsm⁻

2 and is less than 4.0 kNsm<sup>−

2</sup>.

9. A composite material comprising a polymeric material as described according to claim 1 in combination with a filler means.

10. A method of making a component, the method comprising melt processing a polymeric material according to claim 1.

11. A melt processed component comprising a polymeric material according to claim 1.

12. A method of making a component which has a wall which includes a region having a thickness of 3 mm or less, the method comprising:

(A) selecting a precursor material which comprises a polymeric material according to any of claim 1;

AND

(B) treating said precursor material, thereby to form said component.

22. A process according to claim 1, wherein said polymeric material is polyetheretherketone.

13. A process for the preparation of a polymeric material which includes phenyl moieties, ketone moieties and ether moieties in the polymeric backbone of said polymeric material, said process comprising selecting at least one monomer having a moiety of formula

wherein Ph represents a phenyl moiety and wherein said at least one monomer has a purity of at least 99.7 area %.

14. A process according to claim 13, wherein said at least one monomer has a purity of at least 99.85 area %.

15. A process according to claim 13, wherein said at least one monomer has a purity of at least 99.9 area %.

16. A process according to claim 13, wherein said at least one monomer includes at least two phenyl moieties which are unsubstituted, said two phenyl moieties being spaced apart by another atom or group selected from —

O— and

—

CO—

.

17. A process according to claim 13, wherein said at least one monomer comprises phenoxyphenoxybenzoic acid or a benzophenone.

18. A process according to claim 13, wherein said at least one monomer includes a terminal group selected from a halogen atom, an —

OH—

moiety and a —

COOH—

moiety.

19. A process according to claim 13, said process comprising:

(a) polycondensing a compound of general formula

with itself wherein Y¹ represents a halogen atom or a group -EH and Y² represents a halogen atom or a group —

COOH or EH, provided that Y¹ and Y² do not together represent hydrogen atoms;

(b) polycondensing a compound of general formula

with a compound of formula

and/or with a compound of formula

wherein Y³ represents a halogen atom or a group -EH and X¹ represents the other one of a halogen atom or group -EH and Y⁴ represents a halogen atom or a group -EH and X² represents the other one of a halogen atom or a group -EH;

(c) optionally copolymerizing a product of a process as described in paragraph (a) with a product of a process as described in paragraph (b);

wherein each Ar is independently selected from one of the following moieties (i) to (iv) which is bonded by one or more of its phenyl moieties (preferably in its 4,4′

-positions) to adjacent moieties

wherein each m, n, w, r, s, z, t and v is independently zero or a positive integer;

wherein each G is independently selected from an oxygen or sulphur atom, a direct link or a

—

O-Ph-O—

moiety where Ph represents a phenyl moiety; and

wherein each E is independently selected from an oxygen or sulphur atom or a direct link.

20. A process according to claim 13, wherein said polymeric material comprises a repeat unit of formula

where t, v and b independently represent 0 or 1.

21. A process according to claim 13, wherein said polymeric material is selected from polyetheretherketone, polyetherketone, polyetherketoneketone, polyetheretherketoneketone and polyetherketoneetherketoneketone.