US20080275193A1 - Use of Poly(Biphenyl Ether Sulfone)S - Google Patents

Use of Poly(Biphenyl Ether Sulfone)S Download PDF

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US20080275193A1
US20080275193A1 US12/158,411 US15841106A US2008275193A1 US 20080275193 A1 US20080275193 A1 US 20080275193A1 US 15841106 A US15841106 A US 15841106A US 2008275193 A1 US2008275193 A1 US 2008275193A1
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poly
polymer composition
ether ketone
aryl ether
wear resistance
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Douglas Brademeyer
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Solvay Specialty Polymers USA LLC
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Solvay Advanced Polymer LLC
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Assigned to SOLVAY ADVANCED POLYMERS, L.L.C. reassignment SOLVAY ADVANCED POLYMERS, L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRADEMEYER, DOUGLAS
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C08L71/08Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08L71/10Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • C08L71/12Polyphenylene oxides
    • C08L71/123Polyphenylene oxides not modified by chemical after-treatment
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L81/00Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen or carbon only; Compositions of polysulfones; Compositions of derivatives of such polymers
    • C08L81/06Polysulfones; Polyethersulfones
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C08L71/08Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08L71/10Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C08L71/08Polyethers derived from hydroxy compounds or from their metallic derivatives
    • C08L71/10Polyethers derived from hydroxy compounds or from their metallic derivatives from phenols
    • C08L71/12Polyphenylene oxides

Definitions

  • the present invention relates to a new use of poly(biphenyl ether sulfone)s.
  • Poly(biphenyl ether sulfone)s form a specific class of poly(aryl ether sulfone)s. These amorphous technopolymers are materials of choice notably for the ultimate in toughness with a rather good friction and wear resistance, although lower than those of ultra-performance polymers like poly(aryl ether ketone)s.
  • poly(aryl ether ketone)s offer an exceptional balance of technical properties, namely high melting point, excellent thermal stability and excellent friction and wear resistance.
  • high melting point namely high melting point
  • excellent thermal stability namely high thermal stability
  • excellent friction and wear resistance namely high friction and wear resistance.
  • the somewhat low glass transition of these materials limits theirs use in certain specific applications where the use temperature is above 170° C.: this is primarily because of the loss of modulus as the glass transition is traversed.
  • PAEK's and in particular PEEK, offer indeed among the highest abrasion resistance and are “low sloughing”. These properties make them ideal for applications where particulate generation cannot be tolerated, such as for sensitive electronic components which have very strict requirements for extractables in clean room.
  • adding a poly(biphenyl ether sulfone) to a poly(aryl ether ketone) is likely expected to cause a substantial decrease of the friction and wear resistance, and the skilled in the art would have understood that replacing part of the poly(aryl ether ketone) contained in a poly(aryl ether ketone) composition by a usually more cost-attractive polymer, in particular a poly(biphenyl ether sulfone), should not be an appropriate means to solve the complex problem of reducing the cost of the poly(aryl ether ketone) composition while substantially maintaining the friction and/or wear resistance conferred by the poly(aryl ether ketone).
  • a first aspect of the present invention is directed to the use of an effective amount ( ⁇ ) of a poly(biphenyl ether sulfone) (P2) for diluting a poly(aryl ether ketone) (P1) contained in a polymer composition (C1) consisting of the poly(aryl ether ketone) (P1) and, optionally in addition, one or more ingredients (A) other than the poly(aryl ether ketone) (P1) and the poly(biphenyl ether sulfone) (P2), while at least substantially maintaining the friction and/or wear resistance of the polymer composition (C1) with regard to a surface ( ⁇ ) with regard to which respectively the friction and/or wear resistance of the poly(biphenyl ether sulfone) (P2) are not as good as respectively the friction and/or wear resistance of the poly(aryl ether ketone) (P1).
  • Another aspect of the present invention is directed to a method for diluting a poly(aryl ether ketone) (P1) contained in a polymer composition (C1) while at least substantially maintaining the friction and/or wear resistance of the polymer composition (C1) in the need thereof,
  • said polymer composition (C1) consisting of the poly(aryl ether ketone) (P1) and, optionally in addition, one or more ingredients (A) other than the poly(aryl ether ketone) (P1) and a poly(biphenyl ether sulfone) (P2), said friction and/or wear resistance of the polymer composition (C1) being at least substantially maintained with regard to a surface ( ⁇ ) with regard to which respectively the friction and/or wear resistance of the poly(biphenyl ether sulfone) (P2) are not as good as respectively the friction and/or wear resistance of the poly(aryl ether ketone) (P1), said method comprising diluting the poly(aryl ether ketone) (P1) by an effective amount ( ⁇ ) of the poly(biphenyl ether sulfone) (P2).
  • the polymer composition (C1) may be in the form of a shaped article or part of a shaped article (S1).
  • (C2) the polymer composition which can be obtained after the dilution of the poly(aryl ether ketone) (P1), in contrast with (C1) which denotes the polymer composition before the dilution.
  • a polymer composition (C1) consisting of 100 parts by weight (pbw.) of the poly(aryl ether ketone) (P1) and, optionally in addition, one or more ingredients (A) other than the poly(aryl ether ketone) (P1) and the poly(biphenyl ether sulfone) (P2)
  • a polymer composition (C2) consisting of:
  • Still another aspect of the present invention is directed to a shaped article or to a part of a shaped article (S2) composed of the polymer composition (C2) as above described.
  • a last aspect of the present invention is directed to an article assembly comprising said part.
  • the expression “for diluting a poly(aryl ether ketone) (P1) contained in a polymer composition (C1)” should herein be understood in its broad sense, namely: “for reducing the concentration of the concentration of the poly(aryl ether ketone) (P1) contained in the polymer composition (C1)”.
  • such dilution can be achieved by replacing part of the poly(aryl ether ketone) (P1) by the poly(biphenyl ether sulfone) (P2).
  • a frequent benefit resulting from the dilution of the “concentrated” polymer composition [namely, the polymer composition (C1)] is that the so-obtained “diluted” polymer composition [namely, the polymer composition (C2)] is more cost-attractive, because poly(biphenyl ether sulfone)(s) are usually not as expensive as poly(aryl ether ketone)s.
  • the polymer composition (C1) may have been prepared and its friction and/or wear resistance may have been assessed by a certain skilled person, before said skilled person uses the poly(biphenyl ether sulfone) (P2) for diluting the poly(aryl ether ketone) (P1) contained in the polymer composition (C1) in accordance with the presently invented use.
  • the friction and/or wear resistance of the polymer composition (C1) are at least essentially maintained, i.e. the polymer composition (C2) has usually respectively a friction and/or wear resistance with regard to the surface ( ⁇ ) which are the same or essentially the same as those of polymer concentration (C1), or they are greater than those of polymer concentration (C1).
  • the friction resistance of the polymer composition (C1) with regard to the surface ( ⁇ ) is at least substantially maintained; in this embodiment, the wear resistance may be maintained or not.
  • At least the wear resistance of the polymer composition (C1) with regard to the surface ( ⁇ ) is at least substantially maintained; in this embodiment, the friction resistance may be maintained or not.
  • both the friction and the wear resistance of the polymer composition (C1) with regard to the surface ( ⁇ ) are at least substantially maintained.
  • the effective amount ( ⁇ ) of the poly(biphenyl ether sulfone) (P2) can dilute the poly(aryl ether ketone) (P1) contained in the polymer composition (C1) in an amount of 100 parts by weight (pbw.), by replacing, in said polymer composition (C1), ⁇ pbw. of the poly(aryl ether ketone) (P1) by ⁇ pbw. of the poly(biphenyl ether sulfone) (P2); thereby, a polymer composition (C2) containing (100- ⁇ ) pbw. of the poly(aryl ether ketone) (P1) and ⁇ pbw. of the poly(biphenyl ether sulfone) (P2) can be obtained.
  • can range between 0 and 100 pbw.
  • can be as low as technically feasible, but amounts ⁇ of poly(biphenyl ether sulfone) (P2), as defined in the previous paragraph, below than 1 pbw., are rarely desirable, because the so-achieved benefits of the dilution are in this case usually marginal.
  • the effective amount ( ⁇ ) of the poly(biphenyl ether sulfone) (P2) is preferably above 2 pbw.; very preferably, it is above 5 pbw.
  • the effective amount ( ⁇ ) should usually not exceed a certain upper limit, which depends notably on the nature of the poly(biphenyl ether sulfone), the nature of the poly(aryl ether ketone), the nature and amount of optional ingredient(s) (A), and the nature of the surface ( ⁇ ).
  • the friction and/or wear resistance of the polymer composition (C1) are at least maintained or, at least substantially maintained [exhibiting a “plateau” or “quasi-plateau” behaviour], as long as the amount of the poly(biphenyl ether sulfone) (P2) does not exceed a critical limit, above which the friction and/or wear resistance decrease substantially, sometimes in a sharp manner, to reach finally a level close to those of the poly(biphenyl ether sulfone) (P1); the overall friction and/or wear resistance curves [i.e. from 0 to 100 parts of the poly(aryl ether ketone) (P1) replaced, weight pro weight, by the poly(biphenyl ether sulfone) (P2)] may sometimes look like a sigmoid
  • is preferably below 40 pbw.; in still certain other embodiments, ⁇ is preferably below 35 pbw.; in still certain other embodiments, ⁇ is preferably below 30 pbw.; in still certain other embodiments, ⁇ is preferably below 25 pbw.; in still certain other embodiments, ⁇ is preferably below 20 pbw.; in still certain other embodiments, ⁇ is preferably below 15 pbw.
  • the polymer compositions (C1) and (C2) are susceptible of moving temporarily or permanently along the surface ( ⁇ ); often, such temporary or permanent movement is effectively achieved.
  • Non limitative examples of materials susceptible of constituting part or all of the surface ( ⁇ ) include metals, steel, bronze and high engineering thermoplastics.
  • the friction and/or wear resistance of the polymer compositions (C1) and (C2) with regard to the surface ( ⁇ ) can be assessed by any suitable parameters, and said parameters themselves can be obtained by any suitable methods.
  • An example of such a method is well known as the “Taber® abrasion test”.
  • Resistance to wear can be defined as the ability of a material to withstand mechanical action such as rubbing scrapping, or erosion; wear can be difficult to compare but haze variation or weight loss are often evaluated.
  • the haze and/or initial weights of the tests specimens are usually measured. Then, the test specimens are usually placed on an abrasion tester; more precisely, a 250, 500, or 1000-gram load is usually placed on top of the abrader wheel. Then, the test specimens are usually allowed to spin for a specified number of revolutions.
  • a poly(biphenyl ether sulfone) is intended to denote a polycondensation polymer of which more than 50 wt. % of the recurring units are recurring units (R2) of one or more formulae containing at least one p-biphenylene group:
  • recurring units (R2) are of one or more formulae of the general type:
  • R 1 through R 4 are —O—, —SO 2 —, —S—, —C( ⁇ O)—, with the proviso that at least one of R 1 through R 4 is —SO 2 — and at least one of R 1 through R 4 is —O—;
  • Ar 1 , Ar 2 and Ar 3 are arylene groups containing 6 to 24 carbon atoms, and are preferably phenylene or p-biphenylene; and a and b are either 0 or 1.
  • recurring units (R2) are chosen from
  • recurring units (R2) are
  • a polyphenylsulfone (PPSU) polymer is intended to denote any polymer of which more than 50 wt. % of the recurring units are recurring units (R2) of formula (2).
  • the poly(biphenyl ether sulfone) (P2) may be notably a homopolymer, a random, alternate or block copolymer.
  • its recurring units may notably be composed of (i) recurring units (R2) of at least two different formulae chosen from formulae (2) to (6), or (ii) recurring units (R2) of one or more formulae (2) to (6) and recurring units (R2*), different from recurring units (R2), such as
  • P2 poly(biphenyl ether sulfone)
  • P2 poly(biphenyl ether sulfone)
  • P2 was a PPSU homopolymer, i.e. a polymer of which essentially all, if not all, the recurring units are of formula (2).
  • RADEL® R polyphenylsulfone from Solvay Advanced Polymers, L.L.C. is an example of a PPSU homopolymer.
  • the poly(biphenyl ether sulfone) (P2) can be prepared by any method. Methods well known in the art are those described in U.S. Pat. Nos. 3,634,355; 4,008,203; 4,108,837 and 4,175,175, the whole content of which is herein incorporated by reference.
  • the polymer composition (C1) contains a poly(aryl ether ketone) (P1).
  • poly(aryl ether ketone) is intended to denote any polymer of which more than 50 wt. % of the recurring units are recurring units (R1) of one or more formulae containing at least one arylene group, at least one ether group (—O—) and at least one ketone group [—C( ⁇ O)—].
  • recurring units (R1) are chosen from:
  • recurring units (R1) are chosen from:
  • recurring (R1) are chosen from:
  • a PEEK polymer is intended to denote any polymer of which more than 50 wt. % of the recurring units are recurring units (R1) of formula (VII).
  • the poly(aryl ether ketone) (P1) may be notably a homopolymer, a random, alternate or block copolymer.
  • the poly(aryl ether ketone) (P1) may notably contain (i) recurring units (R1) of at least two different formulae chosen form formulae (VI) to (XXI), or (ii) recurring units (R1) of one or more formulae (VI) to (XXI) and recurring units (R1*) different from recurring units (R1).
  • the poly(aryl ether ketone) (P1) has a reduced viscosity (RV) of advantageously at least 0.55 dl/g and preferably of at least 0.70 dl/g; besides, the RV of the poly(aryl ether ketone) (P1) is advantageously of at most 1.10 dl/g and preferably of at most 0.90 dl/g.
  • the poly(aryl ether ketone) (P1) can be prepared by any method.
  • One well known in the art method contains reacting a substantially equimolar mixture of at least one bisphenol and at least one dihalobenzoid compound or at least one halophenol compound as described in Canadian Pat. No. 847,963.
  • Preferred bisphenols in such a process are hydroquinone, 4,4′-dihydroxybiphenyl and 4,4′-dihydroxybenzophenone;
  • preferred dihalobenzoid compounds in such a process are 4,4′-difluorobenzophenone, 4,4′-dichlorobenzophenone and 4-chloro-4′-fluorobenzophenone;
  • preferred halophenols compounds in such a process are 4-(4-chlorobenzoyl)phenol and (4-fluorobenzoyl)phenol.
  • PEEK homopolymers may notably be produced by the nucleophilic process as described in, for example, U.S. Pat. No. 4,176,222, the whole content of which is herein incorporated by reference.
  • PEEK homopolymers comprises electrophilically polymerizing phenoxyphenoxybenzoic acid, using an alkane sulfonic acid as solvent and in the presence of a condensing agent, as the process described in U.S. Pat. No. 6,566,484, the whole content of which is herein incorporated by reference.
  • Other poly(aryl ether ketone)s may be produced by the same method, starting from other monomers than phenoxyphenoxybenzoic acid, such as those described in U.S. Pat. Appl. 2003/0130476, the whole content of which is also herein incorporated by reference.
  • the polymer compositions (C1) and (C2) may further contain conventional ingredients of poly(aryl ether ketone) compositions, including lubricating agents, heat stabilizers, anti-static agents, organic and/or inorganic pigments like TiO 2 , carbon black, acid scavengers, such as MgO, stabilizers, i.e. metal oxides and sulphides such as zinc oxide and zinc sulphide, antioxidants, flame retardants, smoke-suppressing agents, and fillers, collectively referred to as ingredients (A).
  • ingredients (A) collectively referred to as ingredients (A).
  • ingredients (A) are present, their weight, based on the total weight of the polymer composition (C1) [or based on the total weight of the polymer composition (C2)], is advantageously below 50%, preferably below 30%, more preferably below 10% and still more preferably below 5%. Excellent results were observed when the polymer compositions (C1) and (C2) were free of ingredients (A), i.e. they consisted of the poly(aryl ether ketone) (P1) and the poly(biphenyl ether sulfone) (P2).
  • the polymer compositions (C1) and (C2) can be prepared by any conventional mixing method.
  • a preferred method contains dry mixing the ingredients of the polymer compositions of concern in powder or granular form, using e.g. a mechanical blender, then extruding the mixture into strands and chopping the strands into pellets.
  • Non limitative examples of parts of shaped articles or shaped articles or assemblies of shaped articles susceptible of being in accordance with the present invention include bearings, anti-friction bearing cages, metal polymer bearings, thrust washers, brush washers, bushings, seal rings, slides, cable carriers, ball bearing balls, cam followers and gears.
  • Other ones are electronic components or devices, including semiconductor chips, connectors such as electrical plug-in connectors and mono-block electrical connectors, capacitors, light emitting diodes (LEDs), relays, sensors, coils, switches, electronic substrates such as printed circuit boards (PCB), retention members for electrical contacts, integrated circuit test sockets, high temperature resistant bobbins for relays and solenoids, trimming potentiometer rotors, sensor housing and covers, and substrates for hole or surface mounting.
  • connectors such as electrical plug-in connectors and mono-block electrical connectors, capacitors, light emitting diodes (LEDs), relays, sensors, coils, switches, electronic substrates such as printed circuit boards (PCB), retention members for electrical contacts, integrated circuit test sockets, high temperature resistant bobbins for relays and solenoids, trimming potentiometer rotors, sensor housing and covers, and substrates for hole or surface mounting.
  • connectors such as electrical plug-in connectors and mono-block electrical connectors
  • capacitors such as light emitting diodes (
  • polymer compositions were prepared by blending PEEK with PPSU in various amounts, namely polymer compositions E1, E2, E3, E4 and E5.
  • the nature and amount of all the ingredients contained in the exemplified polymer compositions are listed in table 1.
  • All polymer compositions were prepared by melt compounding the ingredients as listed in Table 1, using a Berstorff 25 mm twin screw extruder having eight barrel segments with seven heated zones and an overall length to diameter ratio of 33:1.
  • the extruder was equipped with a vacuum vent at barrel 6 which was maintained under vacuum during all the compounding runs.
  • the compositions were fed to the extruder by metering the ingredients into the feed throat of the extruder using gravimetric feeders which feed them at the appropriate rates to produce the desired blend ratio in each case.
  • Detailed compounding conditions are shown in Table 2.
  • the compounded resins were stranded into a water trough for cooling and solidification and was then diced into pellets.
  • Taber® abrasion tests were run, using a Taber® abraser equipped with CS-17 “Calibrase” wheels (having a durometer hardness of 72 ⁇ 5, measured using ASTM D-676) and a 1000 g loading weight. All samples were aged for 4 days before testing at Standard Laboratory Atmosphere conditions (23° C. and 50% R.H.). Each sample (4 sq. inch (25.81 cm 2 ) plate having a 1 ⁇ 4 inch diameter (0.63 cm) whole in center) was weighted to the closest 0.1 mg. Samples were then submitted to 2000 cycles (by 4-500 cycles unit). Samples were weighted after each 500 cycles, as well as unabraded control specimens. Weight gain or losses of control specimens were deemed to represent changes in moisture content. Weight losses of the abraded samples were thus corrected by the amount of moisture lost or gained by the unabraded control specimen to arrive at the correct weight of abraded material for each 500 cycles.
  • FIG. 1 provides a graphical representation of these results.
  • the weight after abrasion test/initial weight was plotted versus the PPSU wt. % of the different polymer compositions that were tested.

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US20190169430A1 (en) * 2006-03-17 2019-06-06 Solvay Advanced Polymers, L.L.C. Polymer composition
CN114641518A (zh) * 2019-11-08 2022-06-17 索尔维特殊聚合物美国有限责任公司 聚芳醚酮共聚物的共混物

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EP2290001B1 (en) 2009-08-20 2017-10-11 Solvay Specialty Polymers USA, LLC. Use of engineering polymer compositions for the manufacture of high performance films
US8668976B2 (en) * 2011-01-19 2014-03-11 Xerox Corporation Intermediate transfer member and composition
JP2014098064A (ja) * 2012-11-13 2014-05-29 Shin Etsu Polymer Co Ltd 被覆用フィルム、被覆用粘着フィルム、フィルム基材、粘着ラベル及び積層フィルム
JP7092661B2 (ja) * 2015-09-09 2022-06-28 ソルベイ スペシャルティ ポリマーズ ユーエスエー, エルエルシー 強靱化ポリ(アリールエーテルスルホン)/ポリ(アリールエーテルケトン)ブレンド
KR20210027418A (ko) 2018-06-29 2021-03-10 다우 글로벌 테크놀로지스 엘엘씨 중합체의 비정질 함량의 결정

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