Highly filled injection moldable polyetherketones
First Claim
1. A polymer composite for molding articles having improved strength and resistance to heat distortion comprising:
- a) a partially crystalline and partially amorphous polyaryletherketone polymer,b) a reinforcing fiber for providing strength and stiffness to the molded article,c) an immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer to provide additional stiffness and dimensional stability at elevated temperatures, andd) said reinforcing fiber and said immobilizing filler forming at least 40% of the volume of the composite and raising the heat distortion temperature at 264 psi of the composite to above 300°
C. and having a melt viscosity of less than 10,000 poise at 1000 sec-1 at 430°
C.
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Abstract
Injection moldable, highly filled polymer composites are provided which exhibit high dimensional stability at temperatures above the glass transition temperature of the matrix polymer. The heat distortion temperature of the composites approaches that of the crystal melting temperature of the matrix polymer. The composite includes a polyaryletherketone matrix and at least two types of fillers each providing unique properties. The first filler is a reinforcing fiber filler which provides high strength and stiffness. The second filler is an non-thermoplastic immobilizing filler to immobilize the amorphous portion of the partially crystalline polyaryletherketone polymer and provide resistance to high temperature distortion. Notwithstanding its improved mechanical and heat resistant properties, the composite remains injection moldable and thus capable of low cost manufacturing.
60 Citations
20 Claims
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1. A polymer composite for molding articles having improved strength and resistance to heat distortion comprising:
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a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness to the molded article, c) an immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer to provide additional stiffness and dimensional stability at elevated temperatures, and d) said reinforcing fiber and said immobilizing filler forming at least 40% of the volume of the composite and raising the heat distortion temperature at 264 psi of the composite to above 300°
C. and having a melt viscosity of less than 10,000 poise at 1000 sec-1 at 430°
C. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A polymer composite for molding articles having improved strength and resistance to heat distortion, formed from a homogenous mixture comprising:
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a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber for providing strength and stiffness, said reinforcing fiber comprising less than 25% by volume of the article. c) a non-thermoplastic immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, said immobilizing filler being selected from the group consisting of equi-axed and platelet shaped materials; and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300°
C. and within 20°
C. of the crystalline melting point of the polyaryletherketone polymer and having a melt viscosity of less than 10,000 poise at 1000 sec-1 at 430°
C. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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19. A polymer composite for producing melt processable articles having improved strength and resistance to heat distortion formed from a homogenous mixture comprising:
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a) a partially crystalline and partially amorphous polyaryletherketone polymer, b) a reinforcing fiber filler for providing strength and stiffness, said filler comprising less than 25% by volume of the article. c) a platelet shaped immobilizing filler for immobilizing the amorphous portion of the polyaryletherketone polymer, and d) said reinforcing fiber and said immobilizing filler forming at least 40% by volume of the composite and raising the heat distortion temperature of the composite at 264 psi to above 300°
C. and having a melt viscosity of less than 10,000 poise at 1000 sec-1 at 430°
C. - View Dependent Claims (20)
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Specification