Victrex Manufacturing Limited

Adam Chaplin

Ulutan Tahsin

Richard Luke Ainsworth

Alice Victoria Mary Matthews

Brian Wilson

Carlo Capra

Carlie Ann Beardsall

Martin Riley

Alan Wood

Chantelle Duckworth

Nigel Slater

Michael David Benstead

Erin Bryce

Don Thomas

Jason Bell

Michael Lewis Turner

Samuel Lowe

Graham Webster

William Greene

Jack Atkin

Kathryn Warmington

John Grasmeder

Stuart Fenton

Connor Dallas

Samuel Hoggarth

Oliver Carrdus

James Simmonite

Gayle Simpson

A polyaryletherketone PAEK polymeric material and use thereof is disclosed, the polymeric material comprising a homopolymer and/or a copolymer, suitable for use in an additive manufacturing process to make an object. The PAEK polymeric material has a shear viscosity, SV, of at least 145 Pa·s and less than 350 Pa·s, measured using capillary rheometry operating at 400° C. at a shear rate of 1000 susing a circular cross-section tungsten carbide die, 0.5 mm (capillary diameter)×8 mm (capillary length). The PAEK polymeric material has an isothermal crystallinity half life, T, of greater than 12 minutes at a temperature of 280° C., measured by Differential Scanning Calorimetry, DSC.

Polymeric material and use thereof

This invention relates to copolymers which consist essentially of [-ether-phenyl-ether-phenyl-carbonyl-phenyl-]and [ether-phenyl-phenyl-ether-phenyl-carbonyl-phenyl-] repeat units, as well as end units, which have reduced melting temperature (Tm) compared to prior art copolymers including such repeat units. The copolymers of the invention exhibit crystallinity and have similar glass transition temperatures to the prior art polymers.

Copolymers, their preparation and use

A polyaryletherketone, PAEK, in the form of particles is a copolymer with at least 95 mole % repeat units of formula I, and repeat units of formula II, and a molar ratio I:II from 55:45 to 80:20. The PAEK has a melt viscosity, MV, from 0.35 to 0.55 kNsmat 1000 s. The PAEK is of use in formation of components having high elongation at break when formed by selective sintering and melt-bonding of sequentially deposited layers of powder comprising the PAEK particles. Also provided are processes for making the PAEK particles, powders including them and their use and methods of their use in component formation.

Polymeric material, manufacture and use

A method for manufacture of PEEK-PEDEK copolymers is described herein, along with copolymers formed by the method and their use. The method includes a nucleophilic polycondensation of a mixture of dihydroxybenzene and dihydroxybiphenyl with 4,4'-dihalobenzophenone in a reaction mixture comprising sodium carbonate and potassium carbonate, in an aromatic sulfone solvent, at a reaction temperature rising to a temperature from 280° C. to 330° C. immediately prior to the addition of a reaction-stopping salt, such as LiCl or LiSO, to the reaction mixture. Further organic dihalide is subsequently added to the reaction mixture for end-capping of the copolymer. The resulting copolymer has reduced chain branching and reduced melt viscosity at low shear rate compared to prior art copolymer of comparable molecular mass.

Copolymers and process for their manufacture

A polymeric material has a repeat unit of formula &#x2014;O-Ph-O-Ph-CO-Ph- I and a repeat unit of formula &#x2014;O-Ph-Ph-O-Ph-CO-Ph- II wherein Ph represents a phenylene moiety; wherein the repeat units I and II are in the relative molar properties I:II of from 65:35 to 95:5; wherein log(X %)&#x3e;1.50-0.26 MV; wherein X % refers to the % crystallinity measured as described in Example 31 and MV refers to the melt viscosity measured as described in Example 30. A process for making the polymeric material comprises polycondensing a mixture of at least one dihydroxybenzene compound and at least one dihydroxybiphenyl compound in the molar proportions 65:35 to 95:5 with at least one dihalobenzophenone in the presence of sodium carbonate and potassium carbonate wherein: (i) the mole % of said potassium carbonate is at least 2.5 and/or (ii) the following relationship applies 

Polymeric materials

A process for manufacturing an object, the process comprising steps: a) selecting a feedstock material comprising one or more polymeric material selected from i) a polymeric material (A) having a repeat unit of formula I and a repeat unit of formula II wherein Ph represents a phenylene moiety; and/or ii) a polymeric material (B) having a repeat unit of formula III and a repeat unit of formula IV wherein Ph represents a phenylene moiety; each X independently represents an oxygen or suphur atom; n represents an integer of 1 or 2; Y is selected from a phenylene moiety, a Ph-Ph moiety and a naphthalenyl moiety; W is a carbonyl group, an oxygen or sulphur atom, Z is selected from &#x2014;X-Ph-S02-Ph- &#x2014;X-Ph-S02-Y-S02-Ph- and &#x2014;CO-Ph-; b) melting the feedstock material; and c) extruding the feedstock material to form a plurality of parts that define the object.

Polyaryletherketones are produced which are end-capped with a phenylethynyl-containing moiety. The end-capped material, having a relatively low molecular weight, may be subjected to a thermal cycle to produce a higher molecular weight material having excellent mechanical properties, a relatively high level of crystallinity and acceptable Tm and Tg

A polymeric material has a repeat unit of formula &#x2014;O-Ph-O-Ph-CO-Ph-I and a repeat unit of formula &#x2014;O-Ph-Ph-O-Ph-CO-Ph-II wherein Ph represents a phenylene moiety; wherein the repeat units I and II are in the relative molar properties I:II of from 65:35 to 95:5; wherein log(X %)&#x3e;1.50-0.26 MV; wherein X % refers to the % crystallinity and MV refers to the melt viscosity. A process for making the polymeric material is also disclosed.

A process for manufacturing an object by laser sintering comprises: (i) selecting a powder comprising a polymeric material having a repeat unit of formula&#x2014;O&#x2014;Ph&#x2014;O&#x2014;Ph&#x2014;CO&#x2014;Ph&#x2014;&#x2003;&#x2003;Iand a repeat unit of formula&#x2014;O&#x2014;Ph&#x2014;Ph&#x2014;O&#x2014;Ph&#x2014;CO&#x2014;Ph&#x2014;&#x2003;&#x2003;IIwherein Ph represents a phenylene moiety; and (ii) selectively sintering the powder to produce the object. It is found that the polymer used can be advantageously recycled and blended with virgin material to produce a blend which has very similar mechanical properties and crystallinity compared to the virgin material. Thus, the polymer may be cost-effectively used in laser sintering.

Polymeric materials for use in challenging situations in the oil and gas industry (e.g. challenging physical and chemical environments) are described. The polymeric materials comprise a polymeric material having a repeat unit of formula I and a repeat unit of formula II wherein Ph represents a phenylene moiety; wherein the repeat units I and II are in the relative molar proportions 95:5 to 80:20.

Growing community of inventors

Lancashire, United Kingdom

Adam Chaplin