Polyetherketoneketone nonwoven mats

• US 9,422,654 B2
• Filed: 03/18/2010
• Issued: 08/23/2016
• Est. Priority Date: 03/20/2009
• Status: Active Grant

• Current Assignee: Arkema Incorporated (Arkema)
• Original Assignee: Arkema Incorporated (Arkema)
• Inventors: Rudman, Gilbert W., O'Brien, Gregory S., Bertelo, Christopher A.
• Primary Examiner(s): SINGH-PANDEY, ARTI R
• Application Number:
  US13/257,327
• Publication Number:
  US 20120015577A1
• Time in Patent Office: 2,350 Days
• Field of Search: 428/34.1, 428/34.5, 428/34.6, 428/36.9, 428/36.91, 428/398, 428/564, 442/327, 442/334, 442/361, 442/381, 442/392
• US Class Current: 1/1
• CPC Class Codes: C08G 2650/40 containing ketone groups, e.g. polyarylethylketones, PEEK or PEK
• 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: D04H 3/009 Condensation or reaction polymers
• CPC Class Codes: D04H 3/14 with bonds between thermoplastic yarns or filaments produced by welding
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/671 Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material

Abstract

The invention provides nonwoven mats comprising polyetherketoneketone fibers or mixtures thereof. Also provided are filters, textiles, blankets, and insulation prepared from polyetherketoneketone nonwoven mats, as well as methods for manufacturing the same.

Claims

1. A nonwoven mat consisting of first polyetherketoneketone fibers or mixtures thereof, wherein said first polyetherketoneketone has repeating units of isomer T represented by Formula I and a repeating unit of isomer I represented by Formula II:

-A-C(═

O)—

B—

C(═

O)—

 

 

I

-A-C(═

O)-D-C(═

O)—

 

 

II

where A is a -Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene, in a T;

I isomer ratio of from 50;

50 to 90;

10, and wherein said first polyetherketoneketone is semi-crystalline having a crystallinity of from about 10% to about 40% as measured by DSC,

wherein said mixtures consist of said first polyetherketoneketone fibers and one or more second polyether ketoneketone fibers having a different T;

I isomer ratio and/or different crystallinity from said first polyetherketoneketone fibers,

and optionally one or more additives selected from the group consisting of pigments, processing aids, and stabilizers.

2. The nonwoven mat of claim 1, wherein the fibers are monofilaments.

3. The nonwoven mat of claim 1, wherein the fibers are multifilaments.

4. The nonwoven mat of claim 1, wherein the polyetherketoneketone or mixture thereof has a crystallinity, as measured by DSC, of from about 30% to about 35%.

5. An article comprising at least one nonwoven mat according to claim 1, wherein the article is selected from a filter or blanket.

6. A textile comprising at least one nonwoven mat according to claim 1.

7. The nonwoven mat of claim 1 comprising at least one core layer consisting of said first polyetherketoneketone fibers or mixtures thereof and at least one shell layer consisting of said first polyetherketoneketone fibers or mixtures thereof, wherein the polyetherketoneketone or mixture thereof present in the shell layer has a lower T:

I isomer ratio than the polyetherketoneketone or mixture thereof present in the core layer.

8. The nonwoven mat of claim 7, wherein the core layer polyetherketoneketone or mixture thereof has a T:

I isomer ratio of at least about 60;

40.

9. The nonwoven mat of claim 7, wherein the core layer polyetherketoneketone or mixture thereof has a T:

I isomer ratio of about 80;

20.

10. The nonwoven mat of claim 7, wherein the shell layer polyetherketoneketone or mixture thereof has a T:

I ratio less than about 60;

40.

11. A nonwoven mat comprising at least two sections consisting of polyetherketoneketone fibers or mixtures thereof and optionally one or more additives selected from the group consisting of pigments, processing aids, and stabilizers, wherein the polyetherketoneketones or mixtures thereof have repeating units represented by Formula I (isomer T) and Formula II (isomer I):

-A-C(═

O)—

B—

C(═

O)—

 

 

I

-A-C(═

O)-D-C(═

O)—

 

 

II

where A is a -Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene, in a T;

I isomer ratio of from 50;

50 to 90;

10, and wherein said polyetherketoneketone is semi-crystalline having a crystallinity of from about 10% to about 40% as measured by DSC; and

wherein at least one section of polyetherketoneketone fibers or mixtures thereof has a lower T;

I isomer ratio relative to the polyetherketoneketone fibers or mixtures thereof of another section.

12. The nonwoven mat of claim 11, wherein at least one section of polyetherketoneketone fibers or mixtures thereof has a T:

I isomer ratio of at least about 60;

40, and at least one section of polyetherketoneketone fibers or mixtures thereof has a T;

I isomer ratio of less than about 60;

40.

17. The nonwoven mat of claim 11, wherein the polyetherketoneketone or mixture thereof has a crystallinity, as measured by DSC, of from about 30% to about 35%.

13. A nonwoven mat comprising a first layer consisting of polyetherketoneketone fibers or mixtures thereof and optionally one or more additives selected from the group consisting of pigments, processing aids, and stabilizers and a second layer consisting of polyetherketoneketone fibers or mixtures thereof and optionally one or more additives selected from the group consisting of pigments, processing aids, and stabilizers, wherein the polyetherketoneketones or mixtures thereof have repeating units represented by Formula I (isomer T) and Formula II (isomer I):

-A-C(═

O)—

B—

C(═

O)—

 

 

I

-A-C(═

O)-D-C(═

O)—

 

 

II

where A is a -Ph-O-Ph- group, Ph is a phenylene radical, B is p-phenylene, and D is m-phenylene, in a T;

I isomer ratio of from 50;

50 to 90;

10, and wherein said polyetherketoneketone is semi-crystalline having a crystallinity of from about 10 to about 40% as measured by DSC; and

wherein the second layer polyetherketoneketone fibers or mixtures thereof have a lower T;

I isomer ratio relative to the first layer polyetherketoneketone fibers or mixtures thereof.

14. The nonwoven mat of claim 13, wherein the first layer polyetherketoneketone fibers or mixtures thereof have a T:

I isomer ratio at least about 60;

40.

15. The nonwoven mat of claim 13, wherein the first layer polyetherketoneketone fibers or mixtures thereof have a T:

I isomer ratio of about 80;

20.

16. The nonwoven mat of claim 13, wherein the second layer polyetherketoneketone fibers or mixtures thereof have a T:

I isomer ratio less than about 60;

40.